EP1003990B1 - Electromagnetically actuated disc-type valve - Google Patents
Electromagnetically actuated disc-type valve Download PDFInfo
- Publication number
- EP1003990B1 EP1003990B1 EP98931257A EP98931257A EP1003990B1 EP 1003990 B1 EP1003990 B1 EP 1003990B1 EP 98931257 A EP98931257 A EP 98931257A EP 98931257 A EP98931257 A EP 98931257A EP 1003990 B1 EP1003990 B1 EP 1003990B1
- Authority
- EP
- European Patent Office
- Prior art keywords
- armature
- valve
- valve seat
- core member
- disposed
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Lifetime
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Classifications
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16K—VALVES; TAPS; COCKS; ACTUATING-FLOATS; DEVICES FOR VENTING OR AERATING
- F16K31/00—Actuating devices; Operating means; Releasing devices
- F16K31/02—Actuating devices; Operating means; Releasing devices electric; magnetic
- F16K31/06—Actuating devices; Operating means; Releasing devices electric; magnetic using a magnet, e.g. diaphragm valves, cutting off by means of a liquid
- F16K31/0644—One-way valve
- F16K31/0655—Lift valves
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
- F02M—SUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF
- F02M51/00—Fuel-injection apparatus characterised by being operated electrically
- F02M51/06—Injectors peculiar thereto with means directly operating the valve needle
- F02M51/061—Injectors peculiar thereto with means directly operating the valve needle using electromagnetic operating means
- F02M51/0625—Injectors peculiar thereto with means directly operating the valve needle using electromagnetic operating means characterised by arrangement of mobile armatures
- F02M51/0635—Injectors peculiar thereto with means directly operating the valve needle using electromagnetic operating means characterised by arrangement of mobile armatures having a plate-shaped or undulated armature not entering the winding
- F02M51/0639—Injectors peculiar thereto with means directly operating the valve needle using electromagnetic operating means characterised by arrangement of mobile armatures having a plate-shaped or undulated armature not entering the winding the armature acting as a valve
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
- F02M—SUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF
- F02M61/00—Fuel-injectors not provided for in groups F02M39/00 - F02M57/00 or F02M67/00
- F02M61/16—Details not provided for in, or of interest apart from, the apparatus of groups F02M61/02 - F02M61/14
- F02M61/165—Filtering elements specially adapted in fuel inlets to injector
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
- F02M—SUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF
- F02M61/00—Fuel-injectors not provided for in groups F02M39/00 - F02M57/00 or F02M67/00
- F02M61/16—Details not provided for in, or of interest apart from, the apparatus of groups F02M61/02 - F02M61/14
- F02M61/168—Assembling; Disassembling; Manufacturing; Adjusting
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
- F02M—SUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF
- F02M61/00—Fuel-injectors not provided for in groups F02M39/00 - F02M57/00 or F02M67/00
- F02M61/16—Details not provided for in, or of interest apart from, the apparatus of groups F02M61/02 - F02M61/14
- F02M61/18—Injection nozzles, e.g. having valve seats; Details of valve member seated ends, not otherwise provided for
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16K—VALVES; TAPS; COCKS; ACTUATING-FLOATS; DEVICES FOR VENTING OR AERATING
- F16K31/00—Actuating devices; Operating means; Releasing devices
- F16K31/02—Actuating devices; Operating means; Releasing devices electric; magnetic
- F16K31/06—Actuating devices; Operating means; Releasing devices electric; magnetic using a magnet, e.g. diaphragm valves, cutting off by means of a liquid
- F16K31/0644—One-way valve
- F16K31/0651—One-way valve the fluid passing through the solenoid coil
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
- F02M—SUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF
- F02M2200/00—Details of fuel-injection apparatus, not otherwise provided for
- F02M2200/50—Arrangements of springs for valves used in fuel injectors or fuel injection pumps
- F02M2200/505—Adjusting spring tension by sliding spring seats
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T137/00—Fluid handling
- Y10T137/794—With means for separating solid material from the fluid
- Y10T137/8122—Planar strainer normal to flow path
Definitions
- the present invention relates to electromagnetically actuated valves and more particularly to such valves of the disc type.
- Valves of this type are also known from the documents US 53 400 32 , US 5544816 , US 5516424 and GB 2144060 .
- the standard fuel injector port in the air manifold has a diameter of 14 mm.
- Disc-type gasoline fuel injectors are known and typically involve a double working pole magnetic circuit.
- the main body portion of the disc-type injector requires a relatively large diameter and cannot be inserted into the standard port. This limits the ability of engine designers in their designs of the air manifold and air inlet.
- a disc-type gasoline fuel injector is disclosed in U.S. Patent No. 4,917,307 to Baxter et al .
- a hollow generally cylindrical outer body 11 formed of magnetic material surrounds a hollow flanged core member 13, also formed of magnetic material.
- a former 16 made of synthetic resin material surrounds core 13, and a solenoid winding 17 is wound around former 16.
- Body 11 defines an integral radially inwardly extending annular shoulder 18.
- An annulus 19 is trapped against annular shoulder 18 by means of a non-magnetic valve seat member 21, which itself is held in position by means of a tubular outlet member 15 which projects into the air inlet manifold of the gasoline engine.
- Seat member 21 is configured in the form of a disc, the diameter of which is equal to the internal diameter of body 11.
- Seat member 21 has a central orifice 22, which is surrounded by an inner annular seat element 23.
- a plate valve member 24 is biased by a spring 26 into contact with inner annular seat element 23, which is disposed within annulus 19.
- valve member 24 has a plurality of openings 25 and is formed of magnetic material so that when winding 17 is energized, the flange 18 and core member 13 assume opposite magnetic polarity.
- the valve member 24 is attracted away from the seat element 21 against the biasing action of the spring 26 so that fuel can flow through the passage 14 and openings 25 to the central orifice 22. Movement of the valve member 24 towards the annular shoulder 18 is limited by a non-magnetic shim (not shown).
- critical dimensions such as the air gap typically are set during manufacture by grading shims or the thickness of other components.
- non-magnetic plates may be inserted on one or both of a moving magnetic pole and a stationary magnetic pole.
- the body 1 houses an annular electromagnet 2 in which a tubular core 3 is disposed.
- the shutter member 4 is fixed to an armature 6 that can be magnetically attracted to the tubular core.
- the injection orifice 5 is formed in an element 8 that is configured with a flat bottom wall that is laser welded to the lower section of an annular wall 7, which is configured with two concentric sections of different diameters.
- the lower section 9 of the annular wall 7 has a relatively smaller diameter than an upper section 10 of the annular wall 7.
- a sealing ring 13 and a spacer washer 14 are disposed between the tubular core 3 and the upper section 10 of the annular wall of the annular ferromagnetic element 7 that partially houses the lower end of the core and partially houses the sealing ring.
- a tubular casing 15 formed of sheet metal contains the annular ferromagnetic element 7 and the tubular core, and the lower end of the casing 15 overlies at least a part of the annular wall 10 of the annular ferromagnetic element 7 and is fixed to the annular wall 10 of the annular ferromagnetic element 7 by means of a laser weld 19.
- a further laser weld 21 attaches the opposite end of the casing 15 to a flange 20 formed in the opposite end of the core.
- a magnetic circuit with a single working-pole is formed within the core 3, the armature 6, and the wall 10 of the ferromagnetic element 7.
- bucket-type injectors while typically having a magnetic circuit with a single working-pole, are noisier and more prone to leakage than disc-type injectors.
- the object of the invention is achieved by an electromagnetically actuatable disc-type valve having the features of claim 1.
- the disc-type valve of the present invention includes a magnetic circuit with a single working pole, which is more efficient than a double working pole circuit that normally is associated with a disc-type fuel injector embodiment of a disc-type valve.
- the magnetic flux travels through the body, the body flange, the core member, the armature, and the magnetic nozzle pole, each of which being formed of magnetic material.
- a guide ring formed of non-magnetic material and having a smaller interior diameter than the interior diameter of the magnetic nozzle pole, prevents physical contact between the armature and the magnetic nozzle pole.
- the lift stop member is also formed of non-magnetic material and is disposed to prevent contact between the armature and the core.
- the thickness of the guide ring is configured in relation to the exterior diameter of the armature, the amount of lift permitted the armature between the lift stop member and the top surface of the valve seat, and the diametrical clearance between the central opening of the guide ring and the armature, so as to preclude jamming of the armature against movement.
- the valve's configuration enables the diameter of the valve body to be kept below 13.5mm.
- the lift stop is welded to the nozzle pole and then welded to the core member.
- the desired air gap between the bottom surface of the core member and the top surface of the armature needs to be precisely controlled.
- the welding of the lift stop member to the exterior surface of the core member can be performed so as to provide the direct control needed to set the air gap with the required accuracy.
- the design of the present invention simplifies the assembly of the valve.
- the bottom surface and the intermediate interior sidewall of the nozzle pole form an intermediate chamber for receiving the guide ring.
- the exterior sidewalls of the nozzle pole and the valve seat at their respective delivery ends, are configured with complementary tapered sidewall surfaces so that they can be assembled by machine easily and accurately.
- the configuration of the valve of the present invention permits the valve to be hermetically sealed by welding.
- the hydraulic sub-assembly comprising the core member, the armature, the lift stop, the guide ring, the magnetic nozzle pole, and the valve seat, can be assembled separately from the electrical sub-assembly comprising the body, the coil, and the plastic jacket covering the body.
- the nozzle pole and the valve seat are configured so that they can be welded to one another without affecting the integrity of the seating of the armature on the sealing land of the valve seat.
- valve's hydraulic sub-assembly is a separately sealed unit
- the hydraulic sub-assembly can be independently checked for such things as lift, leakage, and static flow rate before the hydraulic sub-assembly is added to the electrical sub-assembly.
- valve's plastic jacket is molded around the body of the electrical sub-assembly before the hydraulic sub-assembly is combined with the electrical sub-assembly.
- the hydraulic sub-assembly is not subjected to the heat stresses and pressure stresses that otherwise would occur when the plastic jacket is molded to the body. By thus being shielded from such stresses, the reliability of the aforementioned testing of the hydraulic sub-assembly is maintained.
- valve's filter is inserted into the central passage of the core member before the calibration slide is inserted to set the biasing force on the armature, the flow testing of the valve can occur in the presence of the filter, thus enhancing the reliability of the flow testing of the hydraulic sub-assembly.
- a top bushing connects the hydraulic sub-assembly to the electrical sub-assembly of the valve and enables the distinguishing features of the electrical sub-assembly of the valve to be oriented with respect to the distinguishing features of the hydraulic sub-assembly of the valve before the top bushing is welded into place to fix these desired orientations of the two sub-assemblies relative to one another.
- the manufacture of the valve of the present invention can be accomplished with very few machining operations. This is possible because the core member can be formed of a piece of tubing, as can the body of the injector. Moreover, both the lift stop and the guide ring can be formed of a fine blanked component. Furthermore, the armature can be molded, and only a small amount of secondary machining would be required to finish the outer surfaces of the armature.
- FIG. 1 A preferred embodiment of the electromagnetically actuatable disc-type valve of the present invention is shown in Fig. 1 and is represented generally by the numeral 30.
- the valve can be used for any of a number of applications.
- the valve can be used as a gasoline fuel injector for supplying liquid fuel to an air inlet duct of a spark ignition engine.
- the preferred embodiments described below and shown in the Figs. are in the form of gasoline fuel injectors.
- the electromagnetically actuated disc-type valve of the present invention can be regarded as having two opposite ends, a receiving end (indicated generally in Fig. 1 by the numeral 31) and a delivery end (indicated generally in Fig. 1 by the numeral 32).
- the receiving end is generally disposed externally of the engine and provides connecting sites for attachment to electrical and fuel inputs for the injector.
- the receiving end 31 of the valve 30 consists largely of a plastic jacket 34.
- this plastic jacket which is generally designated by the numeral 34, is formed by a molded plastic component having two branches, a main branch 35 and an auxiliary branch 36.
- the main branch 35 has two opposite ends.
- One end of the valve's main branch 35 houses the connection to the fluid supply for the valve and can include an O-ring 39 and a top bushing 40.
- Some embodiments of the valve can include a color ring 37, but it is not a necessity. However, when provided, color ring 37 is color-coded to enable easy identification of the type of valve.
- top bushing 40 is provided with an end flange 33 that cooperates with plastic jacket 34 or color ring 37 (when provided) to form a groove for receiving O-ring 39.
- the delivery end 32 of the main branch 35 is configured to contain the components of the valve that deliver the fluid in a metered flow. In the injector embodiment, this metered flow of fuel would be delivered to the air intake (not shown) of the engine (not shown).
- the auxiliary branch 36 of plastic jacket 34 houses an electrical connector 57 for supplying electrical power to the wires 55 of an electrical coil assembly 50 (described below).
- two distinct sub-assemblies comprise the valve.
- one sub-assembly is a hydraulic sub-assembly, which is generally designated by the numeral 131.
- Hydraulic sub-assembly 131 includes those components of the valve that pertain to the path taken by fluid through the valve.
- the other sub-assembly is an electrical sub-assembly, which is indicated generally by the designating numeral 132.
- a first component of electrical sub-assembly 132 is provided in the form of a body 42, which is shown in Figs. 1-3B and must be formed from magnetic material.
- the first external diameter of body 42 typically will not exceed 13.3 mm, which is less than the typical external diameter of the delivery end of a conventional injector.
- body 42 desirably is configured in the form of a cylindrical piece of steel tubing having a circular transverse cross-sectional shape symmetrically disposed about a central longitudinal axis 44.
- the exterior surface of body 42 is configured as a right cylinder with a circular transverse cross-section
- the interior surface of body 42 is configured as a right cylinder with a circular transverse cross-section.
- An example of a suitable piece of such tubing has a first internal diameter of 11.6 mm and a first external diameter of 13.2 mm. As shown in Fig.
- the supply end 38 of body 42 is disposed in an annular recession 45 that is formed in the interior of main branch 35 of plastic jacket 34 when plastic jacket 34 is molded around body 42.
- body 42 has a delivery end 41 disposed opposite supply end 38 of body 42.
- the electrical sub-assembly of the electromagnetically actuated disc-type valve of the present invention includes a wire wound into the form of a cylindrical hollow coil for carrying electricity to generate a magnetic field.
- a coil assembly 50 is formed from metal wire 55 that is wound upon a bobbin 52 constructed of electrically insulating material.
- Each of the opposite ends of wire 55 is electrically connected to one of terminal blades 57, which also forms part of coil assembly 50.
- the ends of the coil winding are connected to a control circuit (not shown) via terminal blades 57, which are electrically connected to a cable (not shown).
- the molding process provides a region 54 of electrically insulating material that becomes disposed around wire 55 and internally of body 42. Insulating region 54 physically separates and electrically insulates wire 55 of coil assembly 50 from body 42.
- body 42 defines a cut out 43 disposed near supply end 38 of body 42 to accommodate passage of terminal blades 57 into auxiliary branch 36 of plastic jacket 34 when plastic jacket 34 is molded around coil assembly 50.
- the hydraulic sub-assembly of the electromagnetically actuated disc-type valve includes a core member having an exterior surface that includes a bottom surface.
- the core member forms the single working pole of a magnetic circuit and provides the internal passage for the fluid passing through the valve.
- a core member 46 is disposed symmetrically about central longitudinal axis 44. As shown in Fig. 1 , core member 46 is disposed within body 42 and plastic jacket 34.
- Core member 46 forms part of the magnetic circuit of the valve and therefore must be composed of magnetic material, desirably stainless steel tubing.
- An example of a suitable piece of such tubing has an internal diameter of 3.65 mm and an external diameter of 6.0 mm.
- core member 46 forms an elongated cylindrical hollow member defining an internally disposed central axial passage 48.
- central axial passage 48 extends to a fluid inlet 51, which is connected to a source of fuel under pressure when the valve of the present invention is used as a fuel injector.
- core member 46 is a component of the valve's hydraulic sub-assembly 131
- plastic jacket 34 is a component of the valve's electrical sub-assembly 132.
- these two sub-assemblies 131, 132 of the valve of the present invention are secured to one another in part (at the supply end of the valve) by top bushing 40, which is fixed by welds 29 to core member 46 and inserted into the supply end of plastic jacket 34.
- these welds 29 are produced by a laser welder such as a neodymium doped Yttrium-Aluminum-Garnet (Nd:YAG) laser.
- coiled wire 55 of coil assembly 50 is disposed to surround the delivery end of core member 46.
- a body flange 49 is provided in the form of an annular ring, which is received into jacket 34 and must be formed of magnetic material to complete the magnetic circuit between core member 46 and valve body 42 in plastic jacket 34.
- Body flange 49 also assists during molding in securing bobbin 52 within jacket 34.
- Body flange 49 is of simple construction that does not require any secondary machining.
- a bottom surface 56 of core member 46 desirably is flat. Bottom surface 56 of core member 46 forms one working pole of an electromagnet, which is selectively actuated when the control circuit provides electric power to coil assembly 50 via terminal blades 57.
- the hydraulic sub-assembly of the valve includes another component, which is an armature having a top surface disposed toward the bottom surface of the core member.
- the armature is the only component that moves during operation of the valve and embodies the moving mass of the valve.
- an armature 60 is configured in the form of a disc with a centrally disposed axis 44 of rotation.
- armature 60 has a top surface 61 and is configured with a cylindrically-shaped outer side surface 63 that is disposed parallel to the centrally disposed axis 44.
- armature 60 has a bottom surface 62 disposed to face opposite top surface 61. As shown in Fig. 2 , top surface 61 of armature 60 is disposed toward bottom surface 56 of core member 46. As shown in Fig. 3A , outer side surface 63 extends axially from top surface 61 to bottom surface 62. The axial thickness of outer side surface 63 is measured by a straight side depth dimension. As shown in Fig. 3A , armature 60 also has a circumferential dimension which is defined by the diameter of armature 60. In a presently preferred embodiment, the straight side depth dimension of armature 60 desirably measures 3.0 mm, and the diameter of armature 60 desirably measures 7.2 mm.
- armature 60 can be molded from magnetic material such as three percent silicon iron in a manner so that only a small amount of secondary machining is required to finish the exterior surfaces 61, 62, 63 of armature 60. Magnetic stainless steel also could be used to form armature 60. The provision of a straight side surface 63 in armature 60 eliminates the need for machining that might be required to produce a spherical side surface.
- armature 60 has at least one fluid passage 64 extending generally axially through armature 60.
- armature 60 is configured with a plenum 66, which is generally disposed centrally of armature 60 and that communicates with at least one fluid passage 64 via at least one conduit 68.
- armature 60 has a plurality of fluid passages 64, four being shown in Fig. 3A for example. Each fluid passage 64 is configured and disposed to receive fluid from plenum 66 via a corresponding conduit 68.
- each fluid passage 64 has a cross-sectional area (measured in a plane disposed perpendicular to axis 44) of 0.96 mm 2
- each conduit 68 has a cross-sectional area (measured in a plane disposed parallel to axis 44) of 1.2 mm 2
- the diameter (measured in a plane disposed perpendicular to axis 44) of plenum 66 is 3.4 mm
- the axial depth (measured in a plane disposed parallel to axis 44) of plenum 66 is 1.0 mm.
- the peripheral bottom portion of plenum 66 serves as a spring pocket and thus is configured to receive and support the tensioning spring 88 (described below) of the valve.
- the spring pocket includes at least one spring seat 59, and the spring 88 will be disposed to rest against spring seat 59.
- Four identical spring seats 59 are symmetrically disposed around the inner periphery of plenum 66 shown in the Figs.
- the hydraulic sub-assembly of the valve includes yet another component, which is a magnetic nozzle pole configured in the form of an annular sleeve and disposed to surround the armature and define another part of the magnetic circuit.
- the magnetic nozzle pole must be formed of a magnetic material, desirably magnetic stainless steel.
- an annular magnetic nozzle pole 70 has a top surface 74.
- magnetic nozzle pole 70 has a supply end disposed partially within body 42.
- the supply end of magnetic nozzle pole 70 has a bottom surface 75 disposed opposite to top surface 74.
- an interior wall 71 disposed at the supply end of nozzle pole 70 defines a centrally disposed internal opening having an interior diameter and forming the supply portion 58 of a receiving compartment (described more fully below), which has a circular transverse cross-section (taken in a plane disposed perpendicular to axis 44) defined by an interior diameter.
- Most of armature 60 is disposed within supply portion 58 of the receiving compartment.
- Interior wall 71 of the supply end of magnetic nozzle pole 70 has a cylindrically-shaped interior surface that is parallel to central axis 44. In a presently preferred embodiment shown in Fig.
- the interior diameter of supply portion 58 of the receiving compartment of magnetic nozzle pole 70 measures 7.315 mm, and the magnetic nozzle pole's exterior diameter at the supply end measures 9.19 mm.
- the straight side depth dimension (measured parallel to axis 44) of interior wall 71 of the supply end of magnetic nozzle pole 70 measures 2.5 mm and is also known as the axial thickness of the supply end of magnetic nozzle pole 70.
- the hydraulic sub-assembly of the valve includes still another component, which is a guide ring configured in the form of an annular ring.
- the guide ring is formed of non-magnetic material such as non-magnetic stainless steel and is configured and disposed to prevent physical contact between the armature and the magnetic nozzle pole. In particular, such physical contact is prevented when the core member is energized so that the armature, the magnetic nozzle pole and the core member form part of a magnetic circuit.
- a guide ring 76 is configured in the form of an annular ring and has a top surface 78 and a bottom surface 79 opposed to top surface 78.
- Guide ring 76 has a centrally disposed opening defined by an interior wall 77.
- the axial length of interior wall 77 defines the thickness of guide ring 76 along the axial direction, and in the embodiment shown measures 0.55 mm and extends from top surface 78 to bottom surface 79.
- Guide ring 76 can desirably be formed of a fine blanked component having an internal diameter of 7.215 mm and an external diameter of 9.19 mm.
- top surface 78 of guide ring 76 is disposed to contact and rest beneath a bottom surface 75 of magnetic nozzle pole 70.
- the opening defined by interior wall 77 is coaxial with the opening defined by interior wall 71 disposed at the supply end of nozzle pole 70. These two openings cooperate to form a receiving compartment in which armature 60 is disposed.
- the thickness of guide ring 76 desirably is configured in relation to the exterior diameter of armature 60, the amount of lift permitted the armature 60, and the diametrical clearance between the interior wall 77 of guide ring 76 and the armature 60 so as to preclude jamming of the armature 60 that otherwise might prevent armature 60 from moving axially.
- the armature of the valve of the present invention is thicker than the normal thickness of an armature in a conventional electromagnetically actuated disc-type valve
- the armature of the present invention is centered by a very thin guide ring.
- the guide ring is positioned to guide the armature by contacting the portion of the armature disposed farthest away from the attractive magnetic nozzle pole formed by core member 46 when coil assembly 50 is supplied with electric current.
- the armature may tilt as it lifts toward bottom surface 56 of core member 46, the maximum tilt of the armature is determined in part by the armature's external diameter and the maximum lift distance of the armature.
- armature In addition, several parameters are chosen so as to constrain the maximum tilt of the armature such that the armature cannot jam when undergoing maximum tilting. These parameters are the axial thickness of the guide ring 76, the diametrical clearance between the interior wall 77 of guide ring 76 and the outer side surface 63 of armature 60, and the diametrical clearance between the interior wall 71 of supply end of magnetic nozzle pole 70 and the outer side surface 63 of armature 60.
- guide ring 76 centers armature 60.
- the interior diameter defined by interior wall 77 of guide ring 76 is close to the exterior diameter of armature 60 and smaller than the interior diameter of the supply end of magnetic nozzle pole 70. These clearances help prevent physical contact between armature 60 and magnetic nozzle pole 70.
- each of guide ring 76, magnetic nozzle pole 70, and armature 60 is configured and disposed to prevent physical contact between armature 60 and magnetic nozzle pole 70 when core member 46, armature 60, and magnetic nozzle pole 70 are disposed to form a magnetic circuit with a single working pole.
- each of guide ring 76, magnetic nozzle pole 70 and armature 60 is configured and disposed to prevent armature 60 from jamming even when armature 60 is maximally tilted.
- the hydraulic sub-assembly of the valve includes still another component, which is a lift stop member configured in the form of another annular sleeve.
- the lift stop member is configured and disposed to form the interface between an electrical sub-assembly of the valve and an hydraulic sub-assembly of the valve.
- the lift stop member also is configured and disposed to block the armature from making metal-to-metal contact with the magnetic pole formed by the bottom surface of the core member when the coil is electrified.
- a lift stop member 80 desirably is configured in the form of an annular sleeve.
- lift stop member 80 has a partially castellated lower surface consisting of a repeated pattern of radially extending gaps 81 that do not extend to or communicate with, the exterior side surface 82 of lift stop member 80.
- gaps 81 terminate radially short of the exterior side surface 82 of lift stop member 80.
- lift stop member 80 is turned into a view that permits viewing of gaps 81 and interspersed ribs 83. Gaps 81 are provided to reduce the contact that armature 60 makes with lift stop member 80 and to reduce pumping losses as the armature 60 moves in the vicinity of the lift stop member 80.
- lift stop member 80 has a centrally disposed axial opening defined by an interior side wall 84 and configured to receive the delivery end portion of core member 46 therein. As shown in Fig. 2 , the interior diameter of interior side wall 84 of lift stop 80 is slightly larger than the exterior diameter of core member 46. Lift stop member 80 is formed of non-magnetic material such as non-magnetic stainless steel. As shown in Fig. 2 , lift stop member 80 is configured and disposed to prevent physical contact between armature 60 and bottom surface 56 of core member 46.
- the hydraulic sub-assembly of the valve includes yet another component, which is a valve seat.
- One end of the valve seat is configured with an interior surface forming a receiving chamber disposed to face toward the bottom surface of the armature.
- the opposite end of the valve seat defines an exit opening that is configured and disposed in communication with the receiving chamber.
- valve seat 90 is provided in the form of a disc-shaped member that is disposed at the delivery end 32 ( Fig. 1 ) of the valve.
- valve seat 90 includes an axially extending external flange 86 that is disposed about the periphery of the delivery end of valve seat 90.
- valve seat 90 has a top face (generally designated by the number 91 in Figs. 4 , 6 and 6A ) that is configured to be disposed toward bottom surface 62 of armature 60.
- top face 91 of valve seat 90 defines an interior surface 94 forming a centrally disposed receiving chamber that is configured to receive fluid flowing through fluid passages 64 of armature 60.
- each entrance opening 85 communicates with an exit conduit 87 that is configured to extend generally axially through valve seat 90 and terminate in an exit opening 89.
- each entrance opening 85 communicates with a spray chamber defined by a conically shaped sidewall 96.
- each exit conduit 87 forms a straight tube that has sidewalls configured to extend at the same angle relative to the axis 44 as sidewall 96 of the spray chamber of valve seat 90.
- four sets of entrance openings 85, exit conduits 87, and exit openings 89 are symmetrically disposed through valve seat 90.
- a so-called sealing land 98 is provided on the valve seat's top face 91 and has an upper surface 99 raised above top surface 94 of valve seat 90.
- sealing land 98 is disposed toward bottom surface 62 of armature 60.
- At least one so-called sealing land 98 desirably is provided to surround the entrances to all of the paths that would permit fluid to flow through valve seat 90.
- the paths that would permit fluid to flow through valve seat 90 would include entrance openings 85, exit conduits 87, and exit openings 89.
- sealing land 98 is disposed to surround interior surface of top face 91 of valve seat 90 and block access to entrance openings 85 from fluid passages 64 of armature 60 when bottom surface 62 of armature 60 is resting atop upper surface 99 of sealing land 98.
- top face 91 of valve seat 90 also includes a so-called support land 95 having a support surface 97 raised above top surface 94.
- support surface 97 of support land 95 of valve seat 90 is configured to support and receive the peripheral portion 69 of bottom surface 62 of armature 60.
- sealing land 98 and support land 95 desirably form a unitary structure with valve seat 90.
- support surface 97 of support land lies in the same flat plane as upper surface 99 of sealing land 98 of valve seat 90.
- the hydraulic sub-assembly of the valve includes a means for biasing the bottom surface of the armature against the sealing land of the valve seat.
- this biasing means is at least partly disposed internally of the central fluid passage of the core member.
- the biasing means can be provided by a coiled compression spring 88.
- a forward end of spring 88 is received in plenum 66 of armature 60 and rests against a spring seat 59 of armature 60.
- armature 60 is biased into contact with support surface 97 of support land 95 and upper surface 99 of sealing land 98 of valve seat 90 by means of spring 88.
- spring 88 provides a means of resiliently biasing bottom surface 62 of armature 60 against the respective opposed surfaces of sealing land 98 and support land 95 of valve seat 90. As shown in Fig. 2 , each end of spring 88 is closed on itself and machined in a flat plane.
- support surface 97 of support land 95 of valve seat 90 is configured to support and receive the peripheral portion 69 of bottom surface 62 of armature 60. Otherwise, the repeated downward movements of armature 60 would be stopped solely by contact with upper surface 99 of sealing land 98 and result in excessive wear of sealing land 98 and consequently poor sealing performance of the valve.
- the support surface 97 of support land 95 and the upper surface 99 of sealing land 98 of top face 91 of valve seat 90 permit the top face 91 of valve seat 90 to cooperate with bottom surface 62 of armature 60 to seal off the flow of fluid through the valve of the present invention.
- valve seat 90 is symmetrically disposed about a central longitudinal axis 44.
- the circumferential exterior sidewall of valve seat 90 is stepped in two sections.
- the supply section of the circumferential exterior sidewall of valve seat 90 is defined by a sidewall section 72 having a cylindrical shape defining a first diameter.
- Sidewall section 72 is a straight side that is parallel to central axis 44.
- the delivery section of the circumferential exterior sidewall of valve seat 90 is defined by a sidewall section 73 having a frustroconical cylindrical shape.
- a stepped surface 93 connects sidewall section 72 to sidewall section 73.
- Sidewall section 73 is disposed to extend generally axially at an angle of about 2.5 degrees relative to central axis 44 such that the diameter of sidewall section 73 gradually increases as one proceeds away from stepped surface 93.
- the diameter at any point along sidewall section 73 is always larger than the first diameter of sidewall section 72.
- the delivery end of valve seat 90 defines a generally axially extending exterior surface 73 that is diverging to a second diameter that is larger than the first diameter of sidewall section 72 of the supply end of nozzle pole 70.
- sidewall section 73 can be said to taper toward the first diameter of sidewall section 72.
- the stepped configuration of the circumferential exterior sidewall of valve seat 90 provides greater ease of assembling valve seat 90 into the hydraulic assembly 131 and welding valve seat 90 to nozzle pole 70, thereby reducing the cost to produce the valve.
- valve seat 90 has a bottom surface 92 disposed to face opposite top surface 94. Truncated conically shaped interior sidewall 96 of valve seat 90 is configured in somewhat of a bell-shape and is disposed to have the wider diameter end form a circular exit opening 104 that opens through bottom surface 92 in the fuel injector embodiment shown. However, other configurations for the exit opening 104 of valve seat 90 can be used, and thus the transverse cross-sectional shape of this exit opening 104 can be other than circular. Moreover, as shown in Figs. 2 and 6A for example, exit opening 104 is disposed in communication with conduits 87 and entrance openings 85. Together, exit opening 104, conduits 87 and entrance openings 85 provide valve seat 90 with at least one hole extending completely through valve seat 90 generally in the direction of axis 44.
- nozzle pole 70 has a cylindrically-shaped intermediate interior sidewall 27 that extends from bottom surface 75 for a length that is sufficient to accommodate the axial thickness of guide ring 76.
- intermediate interior sidewall 27 defines an intermediate internal receiving compartment 100 for receiving guide ring 76, which surrounds part of armature 60 internally of guide ring 76.
- nozzle pole 70 has a third interior sidewall 28 that forms a so-called delivery end sidewall 28, which extends from intermediate interior sidewall 27 to the free end of the delivery end of nozzle pole 70.
- Delivery end interior sidewall 28 defines a surface shaped in a frustroconical manner and extending at an angle of about 2.5 degrees relative to central axis 44 so as to mirror the angle of exterior sidewall section 73 of delivery end of valve seat 90.
- the internal diameter defined by delivery end sidewall 28 of nozzle pole 70 in the vicinity of the delivery end of nozzle pole 70 is slightly larger than the largest diameter of exterior sidewall section 73 of valve seat 90.
- the internal diameter defined by delivery end sidewall 28 in the vicinity where delivery end sidewall 28 joins intermediate interior sidewall 27 of nozzle pole 70 is slightly larger than each of the diameter of exterior sidewall section 72 of valve seat 90 and the diameter of exterior sidewall 53 of guide ring 76.
- the receiving chamber 102 defined by delivery end sidewall 28 at the delivery end of nozzle pole 70 houses valve seat 90.
- delivery end sidewall 28 of nozzle pole 70 has a maximum interior diameter of slightly more than 9.2 mm in the vicinity of the delivery end of nozzle pole 70. The difference between the maximum diameter of exterior sidewall section 73 of valve seat 90 at the delivery end of valve seat 90 and the maximum diameter of delivery end sidewall 28 of nozzle pole 70 at the delivery end of nozzle pole 70 is at a minimum in order to facilitate assembly and welding.
- the delivery end of nozzle pole 70 is welded to the external flange 86 of valve seat 90.
- the welds 112 are provided by a laser welder such as a neodymium-doped yttrium-aluminum-garnet (Nd:YAG) laser.
- Nd:YAG neodymium-doped yttrium-aluminum-garnet
- This welding location on external flange 86 of valve seat 90 is sufficiently shielded from support land 95 and sealing land 98 of valve seat 90 so as to avoid adverse effects to sealing land 98 (such as caused by excessive upward bowing of top face 91 of valve seat 90, distortion of top face 91, and all downward bowing of top face 91) of the welding's heat stress that otherwise might cause leakage.
- sealing land 98 Upward bowing of sealing land 98 should be held between one and four microns for optimum sealing between sealing land 98 of valve seat 90 and bottom surface 62 of armature 60.
- distortion is meant that sealing land 98 would be so contorted that no planar line of contact would exist with bottom surface 62 of armature 60.
- the exterior circumferential surface of nozzle pole 70 is configured with a circumferential groove 111 toward the delivery end of nozzle pole 70.
- an external O-ring 116 can be received around this groove 111 of nozzle pole 70.
- O-ring 116 is retained on one end by an end lip 101 of nozzle pole 70.
- O-ring 116 is retained in part by the shoulder 114 formed by the edge of injector body 42.
- an elastomeric seal such as O-ring 116 is used to seal injector 30 in a port of the air inlet of an engine.
- a calibration means is provided for setting the biasing means to apply a desired biasing force so as to hold the bottom surface of the armature in sealing contact with the sealing land of the valve seat.
- a calibration slide is disposed in the core passage 48 to provide a backstop for the biasing means such as spring 88, which applies the axial force that biases the armature 60 against the valve seat 90.
- the calibration slide provides a setting means, which is a means for setting the biasing means, such as the spring, to apply a desired biasing force so as to bias the bottom surface of the armature against the sealing land of the valve seat.
- a calibration slide 125 is desirably formed from an elongated tube of spring steel.
- the hydraulic sub-assembly of the valve includes a means for filtering fluid passing through the central fluid passage of the core member.
- the filtering means desirably is disposed internally of the central fluid passage of the core member.
- the filtering means is further desirably disposed and configured to cooperate with the biasing means so as to bias the bottom surface of the armature against the sealing land of the valve seat.
- the filtering means is desirably disposed between the biasing means and the setting means.
- the filtering means is configured and disposed so that it is already assembled into the valve before the calibration slide is set and by the time the valve is flow tested during setting of the calibration slide to fix the tension applied by the spring to the armature.
- the filtering means includes an elongated filter 120 that is configured to fit within central passage 48 of core member 46.
- the filtering means of the present invention is desirably disposed in central passage 48 of core member 46 closer to the delivery end 32 than to the supply end 31.
- filter 120 is disposed below calibration slide 125 in the sense that filter 120 is disposed closer to supply end 32 than calibration slide 125.
- filter 120 is carried by an elongated holder 118 having a canted compartment 119 for holding filter 120 at an angle with respect to the central longitudinal axis 44.
- Holder 118 also provides a centrally disposed opening (not visible in the views shown in the Figs.) through its longitudinal axis and carries filter 120 so as to ensure that fluid must pass through filter 120 before exiting the holder's conventional opening.
- one end of holder 118 is configured with a sufficient radius and gauge to butt against a rear end of compression spring 88.
- the opposite end of filter holder 118 is configured to butt against one end of a calibration slide 125.
- the relative positions of filter 120 and spring 88 could be reversed so that filter holder 118 butts against armature 60.
- the moving mass is minimized by being restricted to armature 60 and spring 88.
- each end of calibration slide 125 is shaped identically and so that it can be inserted into passage 48 of core member 46 without digging up shavings from the walls of central passage 48. Otherwise, such metal shavings might clog the fluid flow passages of the valve. Moreover, because filter 120 is already in place within passage 48 when calibration slide 125 is inserted, any such metal shavings caused by the insertion of the calibration slide would be caught by filter 120 rather than result in either clogging or fouling either flow passages 64 of armature 60 or conduits 87 of valve seat 90.
- the filter When the valve is flow tested during setting of the calibration slide to fix the tension applied by the spring to the armature, the filter is already installed into the valve. The presence of filter 120 during such flow testing yields a more accurate flow test than if such testing were done without the filter present.
- the configuration of the present invention permits more accurate calibration of the valve than is possible with conventional valve designs.
- the full extent of permissible movement of the armature between its resting position when disposed against the valve seat and its actuated position when disposed against the bottom surface of the lift stop member is known as the "lift” of the armature.
- the "lift” is determined by a consideration of the axial height of the armature in relation to the combined heights of the guide ring and the portion of the magnetic nozzle pole that butts against the guide ring.
- a bottom surface 47 of lift stop member 80 is disposed against top surface 74 of magnetic nozzle pole 70.
- Bottom surface 75 of magnetic nozzle pole 70 is disposed to contact and rest upon a top surface 78 of guide ring 76.
- a bottom surface 79 of guide ring 76 is disposed to contact and rest upon support surface 97 of valve seat 90.
- the axial thickness of armature 60 is about 50 microns less than the sum of the axial thicknesses of interior wall 71 of supply end of nozzle pole 70 and interior wall 77 of guide ring 76. Accordingly, the lift of the armature is about 50 microns and is schematically indicated in Fig. 2 by the axial distance between the parallel straight lines disposed between the opposed arrows and labeled 123.
- a first continuous weld (indicated by the row of slash lines labeled 121) is disposed to fix bottom surface 47 of lift stop member 80 to top surface 74 of nozzle pole 70.
- the welding is performed with a laser welder such as a Nd:YAG welder.
- a laser welder such as a Nd:YAG welder.
- At least a second continuous weld (indicated by the row of slash lines labeled 122) (also desirably laser welds such as Nd:YAG welds) is disposed to fix a portion of interior sidewall surface 84 of lift stop member 80 to a portion of the exterior surface of core member 46. Then guide ring 76 is inserted to rest against bottom surface 75 of the supply end of magnetic nozzle pole 70. Then armature 60 is inserted to rest against bottom surface 47 of lift stop member 80.
- valve seat 90 is inserted.
- the stepped configuration of the circumferential exterior sidewall of valve seat 90 provides greater ease of assembling valve seat 90 into the receiving chamber 102 at the delivery end of nozzle pole 70.
- Nd:YAG welds 112 are used to attach valve seat 90 to the delivery end of nozzle pole 70 and thereby hermetically seal nozzle pole 70 to valve seat 90.
- valve seat 90 forms the bottom boundary of the receiving compartment that houses armature 60.
- the valve is configured to enable accurate and easy setting of the valve's air gap during assembly of the valve.
- the desired "air gap” is the distance between the bottom surface 56 of the core member 46 and the top surface 61 of the armature 60 when the top surface 61 of the armature rests against the bottom surface 47 of the lift stop member 80.
- the air gap 124 is schematically indicated by the parallel straight lines disposed between the opposed arrows and labeled 124.
- the desired air gap is set when a portion of the exterior surface of the core member 46 is welded to the interior sidewall surface 84 of the lift stop member 80.
- the valve of the present invention includes a first plurality of welds 121 disposed to fix lift stop member 80 to top surface 74 of nozzle pole 70, and a second plurality of welds 122 is disposed to fix lift stop member 80 to the exterior surface of core member 46.
- the use of the welder to weld lift stop member 80 to the exterior surface of core member 46 permits direct setting of the air gap 124 defined between top surface 61 of armature 60 and bottom surface 56 of core member 46 when upper surface of armature 60 is positioned against bottom surface 87 of lift stop member 80.
- the welds 121, 122 are configured and disposed to hermetically seal the valve and prevent leakage of the fluid during operation of the valve.
- this air gap 124 needs to be precisely controlled, regardless of the magnitude of the gap required by the particular valve application.
- this air gap 124 is 20 microns plus or minus 6 microns.
- these welds 121, 122 are disposed in a manner whereby lift stop member 80 prevents physical contact between armature 60 and bottom surface 56 of core member 46 when core member 46, armature 60, and magnetic nozzle pole 70 are selectively actuated to form a magnetic circuit.
- core member 46 becomes hermetically sealed to lift stop member 80
- lift stop member 80 becomes hermetically sealed to nozzle pole 70
- nozzle pole 70 becomes hermetically sealed to valve seat 90.
- a first hydraulic sub-assembly 131 includes the armature 60 (not visible in this view), the core member 46, the lift stop member 80, the guide ring 76 (not visible in this view), the magnetic nozzle pole 70, and the valve seat 90 (not visible in this view), all assembled together and hermetically sealed to one another as explained above.
- This hydraulic sub-assembly 131 shown in Fig. 3C can be assembled as a separate unit from electrical sub-assembly 132.
- electrical sub-assembly 132 includes valve body 42, body flange 49, coil assembly 50 (bobbin 52, wire 55, and terminal blades 57), and plastic jacket 34 covering valve body 42. Depending on whether electric current passes through wire 55 and terminal blades 57, hydraulic sub-assembly 131 may be switched from the first operative configuration of the valve to the second operative configuration of the valve.
- Electrical sub-assembly 132 is completed when plastic jacket 34 is molded around coil assembly 50, body flange 49, and body 42. Electrical sub-assembly 132 is configured to receive mechanical insertion of hydraulic sub-assembly 131 into electrical sub-assembly 132. As shown in Fig. 1 , this is accomplished by molding an axially extending central channel 103 in main branch 35 of plastic jacket 34. Core member 46 defines an exterior surface that is configured with the same transverse cross-section as channel 103. This complementary symmetry facilitates mechanical insertion of hydraulic sub-assembly 131 axially into channel 103 of electrical sub-assembly 132. In the embodiment shown, the exterior surface of core member 46 has both a constant cross-sectional shape along the length thereof and a constant diameter along the length thereof.
- the components are configured with cylindrical symmetry having a circular transverse cross-section.
- cylindrical symmetry having a square or triangular or other polygonal transverse cross-section also could be employed.
- the exterior and/or interior surfaces of these components can be provided with different transverse cross-sectional shapes along one or more portions of their lengths.
- the shapes of the various openings and pathways through which fluid passes through the valve can be provided with different transverse cross-sectional shapes along one or more portions of their lengths, and thus need not be circular.
- top bushing 40 is then inserted into receiving end 31 of channel 103 of main branch 35 of plastic jacket 34 and welded to core member 46 at the location generally designated 29 to secure hydraulic sub-assembly 131 to electrical sub-assembly 132.
- core member 46 it becomes possible to orient one or more distinguishing features of hydraulic sub-assembly 131 relative to one or more distinguishing features of electrical sub-assembly 132.
- auxiliary branch 36 which contains terminal blades 57
- spray pattern resulting from discharge of fluid from outlet conduits 87 in valve seat 90 it becomes possible to orient the auxiliary branch 36, which contains terminal blades 57, relative to the spray pattern resulting from discharge of fluid from outlet conduits 87 in valve seat 90.
- top bushing 40 is welded into place to fix these relative orientations of the valve's components.
- valve of the present invention is configured to permit hydraulic sub-assembly 131 to be assembled separately from electrical sub-assembly 132, the valve of the present invention enjoys several advantages over conventional valves.
- the hydraulic sub-assembly 131 is not subjected to the heat stresses and pressure stresses that occur when plastic jacket 34 is molded around supply end 38 of the valve's body 42.
- the separately sealed hydraulic sub-assembly 131 can be independently checked for leakage, static flow rate, and armature lift before being combined with the electrical sub-assembly 132.
- valve of the present invention can be accomplished with very few machining operations. This is possible because core member 46 and body 42 can be cut from a piece of tubing. Moreover, both lift stop member 80 and guide ring 76 can be formed of a fine blanked component. Furthermore, armature 60 can be molded. A small amount of secondary machining is required to finish outer surfaces 61, 62 and 63 of armature 60. Body flange 49 can be formed of a fine blanked component or a powdered metal component.
- armature 60 When this happens, armature 60 will be lifted from support land 95 and sealing land 98 and armature 60 will move vertically toward spring 88, until top surface 61 of armature 60 rests against bottom surface 47 of lift stop member 80 to form air gap 124 therebetween. With the armature magnetically held in this position, the central fluid passage 48 of core member 46 communicates with plenum 66 and passages 64 of armature 60, so that when the armature is lifted from the lands 95, 98, fluid can flow down the central passage 48 of core member 46, into the plenum 66 of the armature 60 and through the passages 64 of the armature and to interior surface 94 of top face 91 of valve seat 90.
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Abstract
Description
- The present invention relates to electromagnetically actuated valves and more particularly to such valves of the disc type.
- Valves of this type are also known from the documents
US 53 400 32 ,US 5544816 ,US 5516424 andGB 2144060 - In a gasoline engine, the standard fuel injector port in the air manifold has a diameter of 14 mm. Disc-type gasoline fuel injectors are known and typically involve a double working pole magnetic circuit. In order to house the structures forming the magnetic circuit and the fuel path of the conventional disc-type injector, the main body portion of the disc-type injector requires a relatively large diameter and cannot be inserted into the standard port. This limits the ability of engine designers in their designs of the air manifold and air inlet. A disc-type gasoline fuel injector is disclosed in
U.S. Patent No. 4,917,307 to Baxter et al . A hollow generally cylindrical outer body 11 formed of magnetic material surrounds a hollow flanged core member 13, also formed of magnetic material. A former 16 made of synthetic resin material surrounds core 13, and a solenoid winding 17 is wound around former 16. Body 11 defines an integral radially inwardly extending annular shoulder 18. An annulus 19 is trapped against annular shoulder 18 by means of a non-magnetic valve seat member 21, which itself is held in position by means of a tubular outlet member 15 which projects into the air inlet manifold of the gasoline engine. Seat member 21 is configured in the form of a disc, the diameter of which is equal to the internal diameter of body 11. Seat member 21 has a central orifice 22, which is surrounded by an inner annular seat element 23. A plate valve member 24 is biased by a spring 26 into contact with inner annular seat element 23, which is disposed within annulus 19. The valve is checked for flow while the tension in spring 26 against valve member 24 is set by staking the calibration slide into the position that yields the desired flow. Then the filter is inserted into the inlet 12 of the body 11. Valve member 24 has a plurality of openings 25 and is formed of magnetic material so that when winding 17 is energized, the flange 18 and core member 13 assume opposite magnetic polarity. The valve member 24 is attracted away from the seat element 21 against the biasing action of the spring 26 so that fuel can flow through the passage 14 and openings 25 to the central orifice 22. Movement of the valve member 24 towards the annular shoulder 18 is limited by a non-magnetic shim (not shown). - In valves of this type, critical dimensions such as the air gap typically are set during manufacture by grading shims or the thickness of other components. For example, non-magnetic plates may be inserted on one or both of a moving magnetic pole and a stationary magnetic pole.
- One attempt at providing a fuel injector of very small size and very simple structure that can be produced at low cost is disclosed in published European patent application publication number
0 536 774 A1 to Babitzka et al . In this bucket-type injector, the body 1 houses an annular electromagnet 2 in which a tubular core 3 is disposed. The shutter member 4 is fixed to anarmature 6 that can be magnetically attracted to the tubular core. The injection orifice 5 is formed in an element 8 that is configured with a flat bottom wall that is laser welded to the lower section of an annular wall 7, which is configured with two concentric sections of different diameters. The lower section 9 of the annular wall 7 has a relatively smaller diameter than an upper section 10 of the annular wall 7. A sealing ring 13 and a spacer washer 14 are disposed between the tubular core 3 and the upper section 10 of the annular wall of the annular ferromagnetic element 7 that partially houses the lower end of the core and partially houses the sealing ring. A tubular casing 15 formed of sheet metal contains the annular ferromagnetic element 7 and the tubular core, and the lower end of the casing 15 overlies at least a part of the annular wall 10 of the annular ferromagnetic element 7 and is fixed to the annular wall 10 of the annular ferromagnetic element 7 by means of a laser weld 19. A further laser weld 21 attaches the opposite end of the casing 15 to a flange 20 formed in the opposite end of the core. A magnetic circuit with a single working-pole is formed within the core 3, thearmature 6, and the wall 10 of the ferromagnetic element 7. However, bucket-type injectors, while typically having a magnetic circuit with a single working-pole, are noisier and more prone to leakage than disc-type injectors. - It is a principal object of the present invention to provide an electromagnetically actuated disc-type valve having a substantially reduced moving mass and superior noise reduction and sealing performance.
- It is still another principal object of the present invention to provide an electromagnetically actuated disc-type valve that does not rely on internally disposed O-rings for sealing.
- It is another principal object of the present invention to provide an electromagnetically actuated disc-type valve having a substantially reduced diameter without sacrificing performance of the valve.
- It also is a principal object of the present invention to provide an electromagnetically actuated disc-type valve having a reduced diameter while achieving improved performance over larger diameter valves.
- It is yet a further principal object of the present invention to provide an electromagnetically actuated disc-type valve with a reduced diameter armature that is relatively thick yet avoids jamming in use.
- It is a further principal object of the present invention to provide a disc-type, gasoline fuel injector having a reduced diameter to permit greater latitude to designers of the air manifold of the gasoline engine.
- It is another principal object of the present invention to provide a disc-type, gasoline fuel injector having a reduced diameter that permits insertion of a greater depth of the injector into the injector port of the air manifold of the gasoline engine than is possible with conventional injectors.
- It is another principal object of the present invention to provide an improved electromagnetically actuated disc-type valve having a magnetic circuit with a single working pole.
- It is yet another principal object of the present invention to provide an electromagnetically actuated disc-type valve having a reduced diameter relative to conventional disc-type valves yet having a magnetic circuit with a single working pole.
- It is still another principal object of the present invention to provide an electromagnetically actuated disc-type valve having a reduced diameter while lending itself to simpler construction and less expensive manufacturing techniques.
- It is yet another principal object of the present invention to provide an electromagnetically actuated disc-type valve that can be fabricated with fewer machining operations.
- It is yet another principal object of the present invention to provide an electromagnetically actuated disc-type valve that is configured so that during manufacture the valve can be checked for leakage, flow rate and armature lift before adding the electrical sub-assembly.
- It is still another principal object of the present invention to provide an electromagnetically actuated disc-type valve that can be calibrated for spring tension with the fluid filter already installed.
- It is a further principal object of the present invention to provide an electromagnetically actuated disc-type valve having a hydraulic sub-assembly that is hermetically sealed and separate from the electrical sub-assembly of the valve.
- It is yet a further principal object of the present invention to provide an electromagnetically actuated disc-type valve having a configuration that lends itself to being assembled by automated assembly operations.
- Additional objects and advantages of the invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention.
- The object of the invention is achieved by an electromagnetically actuatable disc-type valve having the features of claim 1. The disc-type valve of the present invention includes a magnetic circuit with a single working pole, which is more efficient than a double working pole circuit that normally is associated with a disc-type fuel injector embodiment of a disc-type valve. In the single pole magnetic circuit of the present invention, the magnetic flux travels through the body, the body flange, the core member, the armature, and the magnetic nozzle pole, each of which being formed of magnetic material. However, a guide ring formed of non-magnetic material and having a smaller interior diameter than the interior diameter of the magnetic nozzle pole, prevents physical contact between the armature and the magnetic nozzle pole. Similarly, the lift stop member is also formed of non-magnetic material and is disposed to prevent contact between the armature and the core. The thickness of the guide ring is configured in relation to the exterior diameter of the armature, the amount of lift permitted the armature between the lift stop member and the top surface of the valve seat, and the diametrical clearance between the central opening of the guide ring and the armature, so as to preclude jamming of the armature against movement. The valve's configuration enables the diameter of the valve body to be kept below 13.5mm.
- The lift stop is welded to the nozzle pole and then welded to the core member. The combination of these welds together with welds to join the nozzle pole to the valve seat, hermetically seal the valve and prevent leakage of the fluid during operation of the valve. As known, the desired air gap between the bottom surface of the core member and the top surface of the armature needs to be precisely controlled. In the present invention, the welding of the lift stop member to the exterior surface of the core member can be performed so as to provide the direct control needed to set the air gap with the required accuracy.
- The design of the present invention simplifies the assembly of the valve. The bottom surface and the intermediate interior sidewall of the nozzle pole form an intermediate chamber for receiving the guide ring. The exterior sidewalls of the nozzle pole and the valve seat at their respective delivery ends, are configured with complementary tapered sidewall surfaces so that they can be assembled by machine easily and accurately. The configuration of the valve of the present invention permits the valve to be hermetically sealed by welding. Because the welds hermetically seal the hydraulic sub-assembly of the valve, the hydraulic sub-assembly comprising the core member, the armature, the lift stop, the guide ring, the magnetic nozzle pole, and the valve seat, can be assembled separately from the electrical sub-assembly comprising the body, the coil, and the plastic jacket covering the body. The nozzle pole and the valve seat are configured so that they can be welded to one another without affecting the integrity of the seating of the armature on the sealing land of the valve seat.
- Additionally, because the valve's hydraulic sub-assembly is a separately sealed unit, the hydraulic sub-assembly can be independently checked for such things as lift, leakage, and static flow rate before the hydraulic sub-assembly is added to the electrical sub-assembly.
- Moreover, the valve's plastic jacket is molded around the body of the electrical sub-assembly before the hydraulic sub-assembly is combined with the electrical sub-assembly. In this way, the hydraulic sub-assembly is not subjected to the heat stresses and pressure stresses that otherwise would occur when the plastic jacket is molded to the body. By thus being shielded from such stresses, the reliability of the aforementioned testing of the hydraulic sub-assembly is maintained. In addition, since the valve's filter is inserted into the central passage of the core member before the calibration slide is inserted to set the biasing force on the armature, the flow testing of the valve can occur in the presence of the filter, thus enhancing the reliability of the flow testing of the hydraulic sub-assembly.
- A top bushing connects the hydraulic sub-assembly to the electrical sub-assembly of the valve and enables the distinguishing features of the electrical sub-assembly of the valve to be oriented with respect to the distinguishing features of the hydraulic sub-assembly of the valve before the top bushing is welded into place to fix these desired orientations of the two sub-assemblies relative to one another.
- The manufacture of the valve of the present invention can be accomplished with very few machining operations. This is possible because the core member can be formed of a piece of tubing, as can the body of the injector. Moreover, both the lift stop and the guide ring can be formed of a fine blanked component. Furthermore, the armature can be molded, and only a small amount of secondary machining would be required to finish the outer surfaces of the armature.
- The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate one embodiment of the invention and, together with the description, serve to explain the principles of the invention.
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Fig. 1 is a longitudinal cross-sectional view of a preferred embodiment of assembled components of a valve in accordance with the present invention; -
Fig. 2 is a cross-sectional view of the circled portion labeledFig. 2 inFig. 1 configured in a position closed to the flow of fluid; -
Fig. 3A is an exploded perspective assembly view of the components shown inFig. 1 ; -
Fig. 3B is an exploded perspective assembly view of an electrical sub-assembly of components shown inFigs. 1 and3A ; -
Fig. 3C is an exploded perspective assembly view of an hydraulic sub-assembly of components shown inFigs. 1 and3A ; -
Fig. 4 is an exploded perspective top view of an embodiment of the armature component of the valve shown inFig. 1 ; -
Fig. 5 is an exploded perspective bottom view of the embodiment of the armature component shown inFig. 4 ; -
Fig. 6 is a cross-sectional view of the embodiment of the valve seat component shown inFigs. 4 and 5 taken in the direction in whicharrows 6--6 point inFig. 4 ; and -
Fig. 6A is an enlarged partial cross-sectional view of the embodiment of the valve seat component shown inFig. 6 . - Reference now will be made in detail to the presently preferred embodiments of the invention, one or more examples of which are illustrated in the accompanying drawings. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope of the invention as defined by the appended claims. For instance, features illustrated or described as part of one embodiment, can be used on another embodiment to yield a still further embodiment. Thus, it is intended that the present invention cover such modifications and variations as come within the scope of the appended claims and their equivalents. The same numerals are assigned to the same components throughout the drawings and description.
- A preferred embodiment of the electromagnetically actuatable disc-type valve of the present invention is shown in
Fig. 1 and is represented generally by the numeral 30. The valve can be used for any of a number of applications. For example, the valve can be used as a gasoline fuel injector for supplying liquid fuel to an air inlet duct of a spark ignition engine. For purposes of illustrating the structure and function of the valve of the present invention, the preferred embodiments described below and shown in the Figs. are in the form of gasoline fuel injectors. - In general, the electromagnetically actuated disc-type valve of the present invention can be regarded as having two opposite ends, a receiving end (indicated generally in
Fig. 1 by the numeral 31) and a delivery end (indicated generally inFig. 1 by the numeral 32). In the gasoline injector embodiment, the receiving end is generally disposed externally of the engine and provides connecting sites for attachment to electrical and fuel inputs for the injector. As shown inFig. 1 , the receivingend 31 of thevalve 30 consists largely of aplastic jacket 34. As shown inFigs. 3A and3B , this plastic jacket, which is generally designated by the numeral 34, is formed by a molded plastic component having two branches, amain branch 35 and anauxiliary branch 36. Themain branch 35 has two opposite ends. One end of the valve'smain branch 35 houses the connection to the fluid supply for the valve and can include an O-ring 39 and atop bushing 40. Some embodiments of the valve can include acolor ring 37, but it is not a necessity. However, when provided,color ring 37 is color-coded to enable easy identification of the type of valve. As shown inFigs. 1 ,3A and3B ,top bushing 40 is provided with anend flange 33 that cooperates withplastic jacket 34 or color ring 37 (when provided) to form a groove for receiving O-ring 39. - The
delivery end 32 of themain branch 35 is configured to contain the components of the valve that deliver the fluid in a metered flow. In the injector embodiment, this metered flow of fuel would be delivered to the air intake (not shown) of the engine (not shown). Theauxiliary branch 36 ofplastic jacket 34 houses anelectrical connector 57 for supplying electrical power to thewires 55 of an electrical coil assembly 50 (described below). - In accordance with the electromagnetically actuated disc-type valve of the present invention, two distinct sub-assemblies comprise the valve. As shown in
Fig. 3C for example, one sub-assembly is a hydraulic sub-assembly, which is generally designated by the numeral 131.Hydraulic sub-assembly 131 includes those components of the valve that pertain to the path taken by fluid through the valve. - As shown in
Fig. 3B for example, the other sub-assembly is an electrical sub-assembly, which is indicated generally by the designatingnumeral 132. A first component ofelectrical sub-assembly 132 is provided in the form of abody 42, which is shown inFigs. 1-3B and must be formed from magnetic material. In the gasoline fuel injector embodiment, the first external diameter ofbody 42 typically will not exceed 13.3 mm, which is less than the typical external diameter of the delivery end of a conventional injector. - As shown in
Figs. 3A and3B ,body 42 desirably is configured in the form of a cylindrical piece of steel tubing having a circular transverse cross-sectional shape symmetrically disposed about a centrallongitudinal axis 44. In other words, the exterior surface ofbody 42 is configured as a right cylinder with a circular transverse cross-section, and the interior surface ofbody 42 is configured as a right cylinder with a circular transverse cross-section. As such, the cost ofmanufacturing valve body 42 is minimized. An example of a suitable piece of such tubing has a first internal diameter of 11.6 mm and a first external diameter of 13.2 mm. As shown inFig. 1 , thesupply end 38 ofbody 42 is disposed in anannular recession 45 that is formed in the interior ofmain branch 35 ofplastic jacket 34 whenplastic jacket 34 is molded aroundbody 42. As shown inFigs. 1 and3A for example,body 42 has adelivery end 41 disposedopposite supply end 38 ofbody 42. - The electrical sub-assembly of the electromagnetically actuated disc-type valve of the present invention includes a wire wound into the form of a cylindrical hollow coil for carrying electricity to generate a magnetic field. As shown in
Figs. 3A and3B , acoil assembly 50 is formed frommetal wire 55 that is wound upon abobbin 52 constructed of electrically insulating material. Each of the opposite ends ofwire 55 is electrically connected to one ofterminal blades 57, which also forms part ofcoil assembly 50. When the valve is in use, the ends of the coil winding are connected to a control circuit (not shown) viaterminal blades 57, which are electrically connected to a cable (not shown). - As shown in
Fig. 1 , when the coil assembly 50 (includingbobbin 52,wire 55, and terminal blades 57) is molded intoplastic jacket 34, the molding process provides aregion 54 of electrically insulating material that becomes disposed aroundwire 55 and internally ofbody 42. Insulatingregion 54 physically separates and electrically insulateswire 55 ofcoil assembly 50 frombody 42. As shown inFigs. 3A and3B for example,body 42 defines a cut out 43 disposed nearsupply end 38 ofbody 42 to accommodate passage ofterminal blades 57 intoauxiliary branch 36 ofplastic jacket 34 whenplastic jacket 34 is molded aroundcoil assembly 50. - In accordance with the present invention, the hydraulic sub-assembly of the electromagnetically actuated disc-type valve includes a core member having an exterior surface that includes a bottom surface. The core member forms the single working pole of a magnetic circuit and provides the internal passage for the fluid passing through the valve. As embodied herein and shown in
Figs. 1 ,3A and3C , acore member 46 is disposed symmetrically about centrallongitudinal axis 44. As shown inFig. 1 ,core member 46 is disposed withinbody 42 andplastic jacket 34. -
Core member 46 forms part of the magnetic circuit of the valve and therefore must be composed of magnetic material, desirably stainless steel tubing. An example of a suitable piece of such tubing has an internal diameter of 3.65 mm and an external diameter of 6.0 mm. Thus, as shown inFigs. 1 ,3A and3C for example,core member 46 forms an elongated cylindrical hollow member defining an internally disposed centralaxial passage 48. As shown inFigs. 3A and3C for example, centralaxial passage 48 extends to afluid inlet 51, which is connected to a source of fuel under pressure when the valve of the present invention is used as a fuel injector. - As noted above,
core member 46 is a component of the valve'shydraulic sub-assembly 131, andplastic jacket 34 is a component of the valve'selectrical sub-assembly 132. As shown inFig. 1 , these twosub-assemblies top bushing 40, which is fixed by welds 29 tocore member 46 and inserted into the supply end ofplastic jacket 34. Desirably, these welds 29 are produced by a laser welder such as a neodymium doped Yttrium-Aluminum-Garnet (Nd:YAG) laser. - As shown in
Fig. 1 , coiledwire 55 ofcoil assembly 50 is disposed to surround the delivery end ofcore member 46. As shown inFigs. 1 ,3A and3B , abody flange 49 is provided in the form of an annular ring, which is received intojacket 34 and must be formed of magnetic material to complete the magnetic circuit betweencore member 46 andvalve body 42 inplastic jacket 34.Body flange 49 also assists during molding in securingbobbin 52 withinjacket 34.Body flange 49 is of simple construction that does not require any secondary machining. As shown inFig. 2 for example, abottom surface 56 ofcore member 46 desirably is flat.Bottom surface 56 ofcore member 46 forms one working pole of an electromagnet, which is selectively actuated when the control circuit provides electric power tocoil assembly 50 viaterminal blades 57. - In accordance with the present invention, the hydraulic sub-assembly of the valve includes another component, which is an armature having a top surface disposed toward the bottom surface of the core member. Apart from the spring (described below), the armature is the only component that moves during operation of the valve and embodies the moving mass of the valve. As shown in
Figs. 2 and3A , anarmature 60 is configured in the form of a disc with a centrally disposedaxis 44 of rotation. As shown inFig. 3A ,armature 60 has atop surface 61 and is configured with a cylindrically-shapedouter side surface 63 that is disposed parallel to the centrally disposedaxis 44. As shown inFig. 2 ,armature 60 has abottom surface 62 disposed to face oppositetop surface 61. As shown inFig. 2 ,top surface 61 ofarmature 60 is disposed towardbottom surface 56 ofcore member 46. As shown inFig. 3A ,outer side surface 63 extends axially fromtop surface 61 tobottom surface 62. The axial thickness ofouter side surface 63 is measured by a straight side depth dimension. As shown inFig. 3A ,armature 60 also has a circumferential dimension which is defined by the diameter ofarmature 60. In a presently preferred embodiment, the straight side depth dimension ofarmature 60 desirably measures 3.0 mm, and the diameter ofarmature 60 desirably measures 7.2 mm. - Desirably,
armature 60 can be molded from magnetic material such as three percent silicon iron in a manner so that only a small amount of secondary machining is required to finish the exterior surfaces 61, 62, 63 ofarmature 60. Magnetic stainless steel also could be used to formarmature 60. The provision of astraight side surface 63 inarmature 60 eliminates the need for machining that might be required to produce a spherical side surface. - As shown in
Figs. 2 and3A ,armature 60 has at least onefluid passage 64 extending generally axially througharmature 60. As shown inFig. 2 ,armature 60 is configured with aplenum 66, which is generally disposed centrally ofarmature 60 and that communicates with at least onefluid passage 64 via at least oneconduit 68. Desirably,armature 60 has a plurality offluid passages 64, four being shown inFig. 3A for example. Eachfluid passage 64 is configured and disposed to receive fluid fromplenum 66 via a correspondingconduit 68. In a presently preferred fuel injector embodiment, eachfluid passage 64 has a cross-sectional area (measured in a plane disposed perpendicular to axis 44) of 0.96 mm2, eachconduit 68 has a cross-sectional area (measured in a plane disposed parallel to axis 44) of 1.2 mm2, the diameter (measured in a plane disposed perpendicular to axis 44) ofplenum 66 is 3.4 mm, and the axial depth (measured in a plane disposed parallel to axis 44) ofplenum 66 is 1.0 mm. - As shown in
Figs. 2 and3A for example, the peripheral bottom portion ofplenum 66 serves as a spring pocket and thus is configured to receive and support the tensioning spring 88 (described below) of the valve. In the embodiment shown inFig. 3A , the spring pocket includes at least onespring seat 59, and thespring 88 will be disposed to rest againstspring seat 59. Four identical spring seats 59 are symmetrically disposed around the inner periphery ofplenum 66 shown in the Figs. - In accordance with the present invention, the hydraulic sub-assembly of the valve includes yet another component, which is a magnetic nozzle pole configured in the form of an annular sleeve and disposed to surround the armature and define another part of the magnetic circuit. The magnetic nozzle pole must be formed of a magnetic material, desirably magnetic stainless steel. As embodied herein and shown in
Figs. 2 and3A for example, an annularmagnetic nozzle pole 70 has atop surface 74. As shown inFigs. 1 ,2 ,3A and3C ,magnetic nozzle pole 70 has a supply end disposed partially withinbody 42. As shown inFig. 2 for example, the supply end ofmagnetic nozzle pole 70 has abottom surface 75 disposed opposite totop surface 74. - As shown in
Fig. 3A , aninterior wall 71 disposed at the supply end ofnozzle pole 70 defines a centrally disposed internal opening having an interior diameter and forming thesupply portion 58 of a receiving compartment (described more fully below), which has a circular transverse cross-section (taken in a plane disposed perpendicular to axis 44) defined by an interior diameter. Most ofarmature 60 is disposed withinsupply portion 58 of the receiving compartment.Interior wall 71 of the supply end ofmagnetic nozzle pole 70 has a cylindrically-shaped interior surface that is parallel tocentral axis 44. In a presently preferred embodiment shown inFig. 2 for example, the interior diameter ofsupply portion 58 of the receiving compartment ofmagnetic nozzle pole 70 measures 7.315 mm, and the magnetic nozzle pole's exterior diameter at the supply end measures 9.19 mm. In a presently preferred embodiment, the straight side depth dimension (measured parallel to axis 44) ofinterior wall 71 of the supply end ofmagnetic nozzle pole 70 measures 2.5 mm and is also known as the axial thickness of the supply end ofmagnetic nozzle pole 70. - In accordance with the present invention, the hydraulic sub-assembly of the valve includes still another component, which is a guide ring configured in the form of an annular ring. The guide ring is formed of non-magnetic material such as non-magnetic stainless steel and is configured and disposed to prevent physical contact between the armature and the magnetic nozzle pole. In particular, such physical contact is prevented when the core member is energized so that the armature, the magnetic nozzle pole and the core member form part of a magnetic circuit.
- As embodied herein and shown in
Fig. 3A , aguide ring 76 is configured in the form of an annular ring and has atop surface 78 and abottom surface 79 opposed totop surface 78.Guide ring 76 has a centrally disposed opening defined by aninterior wall 77. The axial length ofinterior wall 77 defines the thickness ofguide ring 76 along the axial direction, and in the embodiment shown measures 0.55 mm and extends fromtop surface 78 tobottom surface 79.Guide ring 76 can desirably be formed of a fine blanked component having an internal diameter of 7.215 mm and an external diameter of 9.19 mm. As shown inFig. 2 for example,top surface 78 ofguide ring 76 is disposed to contact and rest beneath abottom surface 75 ofmagnetic nozzle pole 70. - As shown in
Fig. 2 , the opening defined byinterior wall 77 is coaxial with the opening defined byinterior wall 71 disposed at the supply end ofnozzle pole 70. These two openings cooperate to form a receiving compartment in which armature 60 is disposed. The thickness ofguide ring 76 desirably is configured in relation to the exterior diameter ofarmature 60, the amount of lift permitted thearmature 60, and the diametrical clearance between theinterior wall 77 ofguide ring 76 and thearmature 60 so as to preclude jamming of thearmature 60 that otherwise might preventarmature 60 from moving axially. - While the armature of the valve of the present invention is thicker than the normal thickness of an armature in a conventional electromagnetically actuated disc-type valve, the armature of the present invention is centered by a very thin guide ring. Moreover, the guide ring is positioned to guide the armature by contacting the portion of the armature disposed farthest away from the attractive magnetic nozzle pole formed by
core member 46 whencoil assembly 50 is supplied with electric current. While the armature may tilt as it lifts towardbottom surface 56 ofcore member 46, the maximum tilt of the armature is determined in part by the armature's external diameter and the maximum lift distance of the armature. In addition, several parameters are chosen so as to constrain the maximum tilt of the armature such that the armature cannot jam when undergoing maximum tilting. These parameters are the axial thickness of theguide ring 76, the diametrical clearance between theinterior wall 77 ofguide ring 76 and theouter side surface 63 ofarmature 60, and the diametrical clearance between theinterior wall 71 of supply end ofmagnetic nozzle pole 70 and theouter side surface 63 ofarmature 60. - As embodied herein and shown in
Figs. 1 ,2 , and3A ,guide ring 76centers armature 60. As shown inFig. 2 in particular, the interior diameter defined byinterior wall 77 ofguide ring 76 is close to the exterior diameter ofarmature 60 and smaller than the interior diameter of the supply end ofmagnetic nozzle pole 70. These clearances help prevent physical contact betweenarmature 60 andmagnetic nozzle pole 70. Similarly, the axial thickness, ofguide ring 76 is sized in relation to the axial thickness of the supply end ofmagnetic nozzle pole 70 and the axial thickness ofarmature 60 so that whenarmature 60 is attracted towardbottom surface 56 ofcore member 46 and makes its closest approach thereto,armature 60 cannot tilt sufficiently to contactmagnetic nozzle pole 70 or to jam and fail to move in response to the application of magnetic force. Thus, each ofguide ring 76,magnetic nozzle pole 70, andarmature 60 is configured and disposed to prevent physical contact betweenarmature 60 andmagnetic nozzle pole 70 whencore member 46,armature 60, andmagnetic nozzle pole 70 are disposed to form a magnetic circuit with a single working pole. Similarly, each ofguide ring 76,magnetic nozzle pole 70 andarmature 60 is configured and disposed to preventarmature 60 from jamming even whenarmature 60 is maximally tilted. - In accordance with the present invention, the hydraulic sub-assembly of the valve includes still another component, which is a lift stop member configured in the form of another annular sleeve. The lift stop member is configured and disposed to form the interface between an electrical sub-assembly of the valve and an hydraulic sub-assembly of the valve. The lift stop member also is configured and disposed to block the armature from making metal-to-metal contact with the magnetic pole formed by the bottom surface of the core member when the coil is electrified.
- As embodied herein and shown in
Figs. 1 ,2 ,3A and3C , alift stop member 80 desirably is configured in the form of an annular sleeve. As shown inFig. 3A ,lift stop member 80 has a partially castellated lower surface consisting of a repeated pattern of radially extendinggaps 81 that do not extend to or communicate with, theexterior side surface 82 oflift stop member 80. Thus,gaps 81 terminate radially short of theexterior side surface 82 oflift stop member 80. InFig. 3A ,lift stop member 80 is turned into a view that permits viewing ofgaps 81 and interspersedribs 83.Gaps 81 are provided to reduce the contact that armature 60 makes withlift stop member 80 and to reduce pumping losses as thearmature 60 moves in the vicinity of thelift stop member 80. - As shown in
Fig. 3A ,lift stop member 80 has a centrally disposed axial opening defined by aninterior side wall 84 and configured to receive the delivery end portion ofcore member 46 therein. As shown inFig. 2 , the interior diameter ofinterior side wall 84 oflift stop 80 is slightly larger than the exterior diameter ofcore member 46.Lift stop member 80 is formed of non-magnetic material such as non-magnetic stainless steel. As shown inFig. 2 ,lift stop member 80 is configured and disposed to prevent physical contact betweenarmature 60 andbottom surface 56 ofcore member 46. This is especially true whencoil assembly 50 is selectively electrically actuated so thatcore member 46,armature 60, andmagnetic nozzle pole 70 form part of a magnetic circuit withcore member 46 forming a single working pole when coil is electrically actuated. In a presently preferred embodiment,lift stop member 80 has an interior diameter of slightly more than 6.0 mm and an exterior diameter of 9.19 mm. In accordance with the present invention, the hydraulic sub-assembly of the valve includes yet another component, which is a valve seat. One end of the valve seat is configured with an interior surface forming a receiving chamber disposed to face toward the bottom surface of the armature. The opposite end of the valve seat defines an exit opening that is configured and disposed in communication with the receiving chamber. As embodied herein and shown inFigs. 2 and4-6 for example, avalve seat 90 is provided in the form of a disc-shaped member that is disposed at the delivery end 32 (Fig. 1 ) of the valve. As shown inFigs. 2 and5 ,valve seat 90 includes an axially extendingexternal flange 86 that is disposed about the periphery of the delivery end ofvalve seat 90. As embodied herein and shown inFigs. 2 and4 for example,valve seat 90 has a top face (generally designated by thenumber 91 inFigs. 4 ,6 and 6A ) that is configured to be disposed towardbottom surface 62 ofarmature 60. As shown inFig. 6A for example,top face 91 ofvalve seat 90 defines aninterior surface 94 forming a centrally disposed receiving chamber that is configured to receive fluid flowing throughfluid passages 64 ofarmature 60. - As shown in
Figs. 4 and6A for example, at least oneentrance opening 85 is formed throughinterior surface 94. As shown inFig. 6A , entrance opening 85 communicates with anexit conduit 87 that is configured to extend generally axially throughvalve seat 90 and terminate in anexit opening 89. As shown inFigs. 2 ,5 ,6 and 6A for example, each entrance opening 85 communicates with a spray chamber defined by a conically shapedsidewall 96. Moreover, eachexit conduit 87 forms a straight tube that has sidewalls configured to extend at the same angle relative to theaxis 44 assidewall 96 of the spray chamber ofvalve seat 90. In the embodiment shown in the Figs., four sets ofentrance openings 85,exit conduits 87, andexit openings 89 are symmetrically disposed throughvalve seat 90. - As shown in
Figs. 4 and6A for example, a so-called sealingland 98 is provided on the valve seat'stop face 91 and has anupper surface 99 raised abovetop surface 94 ofvalve seat 90. As shown inFig. 2 for example, sealingland 98 is disposed towardbottom surface 62 ofarmature 60. At least one so-called sealingland 98 desirably is provided to surround the entrances to all of the paths that would permit fluid to flow throughvalve seat 90. As shown inFig. 6A for example, the paths that would permit fluid to flow throughvalve seat 90 would includeentrance openings 85,exit conduits 87, andexit openings 89. As shown inFig. 2 , sealingland 98 is disposed to surround interior surface oftop face 91 ofvalve seat 90 and block access toentrance openings 85 fromfluid passages 64 ofarmature 60 whenbottom surface 62 ofarmature 60 is resting atopupper surface 99 of sealingland 98. - As shown in
Figs. 6 and 6A for example,top face 91 ofvalve seat 90 also includes a so-calledsupport land 95 having asupport surface 97 raised abovetop surface 94. As shown inFig. 2 for example,support surface 97 ofsupport land 95 ofvalve seat 90 is configured to support and receive theperipheral portion 69 ofbottom surface 62 ofarmature 60. As shown inFig. 6A for example, sealingland 98 and supportland 95 desirably form a unitary structure withvalve seat 90. In embodiments wherebottom surface 62 ofarmature 60 is flat,support surface 97 of support land lies in the same flat plane asupper surface 99 of sealingland 98 ofvalve seat 90. - In accordance with the present invention, the hydraulic sub-assembly of the valve includes a means for biasing the bottom surface of the armature against the sealing land of the valve seat. Desirably, this biasing means is at least partly disposed internally of the central fluid passage of the core member. As embodied herein and shown in
Fig. 2 for example, the biasing means can be provided by a coiledcompression spring 88. A forward end ofspring 88 is received inplenum 66 ofarmature 60 and rests against aspring seat 59 ofarmature 60. As shown inFig. 2 for example,armature 60 is biased into contact withsupport surface 97 ofsupport land 95 andupper surface 99 of sealingland 98 ofvalve seat 90 by means ofspring 88. Thus,spring 88 provides a means of resiliently biasingbottom surface 62 ofarmature 60 against the respective opposed surfaces of sealingland 98 and supportland 95 ofvalve seat 90. As shown inFig. 2 , each end ofspring 88 is closed on itself and machined in a flat plane. - Accordingly, it is important that
support surface 97 ofsupport land 95 ofvalve seat 90 is configured to support and receive theperipheral portion 69 ofbottom surface 62 ofarmature 60. Otherwise, the repeated downward movements ofarmature 60 would be stopped solely by contact withupper surface 99 of sealingland 98 and result in excessive wear of sealingland 98 and consequently poor sealing performance of the valve. Thesupport surface 97 ofsupport land 95 and theupper surface 99 of sealingland 98 oftop face 91 ofvalve seat 90 permit thetop face 91 ofvalve seat 90 to cooperate withbottom surface 62 ofarmature 60 to seal off the flow of fluid through the valve of the present invention. - As shown in
Fig. 2 for example,valve seat 90 is symmetrically disposed about a centrallongitudinal axis 44. As shown inFigs. 4-6 , the circumferential exterior sidewall ofvalve seat 90 is stepped in two sections. The supply section of the circumferential exterior sidewall ofvalve seat 90 is defined by asidewall section 72 having a cylindrical shape defining a first diameter.Sidewall section 72 is a straight side that is parallel tocentral axis 44. The delivery section of the circumferential exterior sidewall ofvalve seat 90 is defined by asidewall section 73 having a frustroconical cylindrical shape. A stepped surface 93 connectssidewall section 72 tosidewall section 73.Sidewall section 73 is disposed to extend generally axially at an angle of about 2.5 degrees relative tocentral axis 44 such that the diameter ofsidewall section 73 gradually increases as one proceeds away from stepped surface 93. Thus, the diameter at any point alongsidewall section 73 is always larger than the first diameter ofsidewall section 72. In other words, the delivery end ofvalve seat 90 defines a generally axially extendingexterior surface 73 that is diverging to a second diameter that is larger than the first diameter ofsidewall section 72 of the supply end ofnozzle pole 70. Viewed from the extreme delivery end ofvalve seat 90,sidewall section 73 can be said to taper toward the first diameter ofsidewall section 72. The stepped configuration of the circumferential exterior sidewall ofvalve seat 90 provides greater ease of assemblingvalve seat 90 into thehydraulic assembly 131 andwelding valve seat 90 tonozzle pole 70, thereby reducing the cost to produce the valve. - As shown in
Fig. 6 for example,valve seat 90 has abottom surface 92 disposed to face oppositetop surface 94. Truncated conically shapedinterior sidewall 96 ofvalve seat 90 is configured in somewhat of a bell-shape and is disposed to have the wider diameter end form a circular exit opening 104 that opens throughbottom surface 92 in the fuel injector embodiment shown. However, other configurations for the exit opening 104 ofvalve seat 90 can be used, and thus the transverse cross-sectional shape of this exit opening 104 can be other than circular. Moreover, as shown inFigs. 2 and6A for example, exit opening 104 is disposed in communication withconduits 87 andentrance openings 85. Together,exit opening 104,conduits 87 andentrance openings 85 providevalve seat 90 with at least one hole extending completely throughvalve seat 90 generally in the direction ofaxis 44. - As shown in
Fig. 2 ,nozzle pole 70 has a cylindrically-shaped intermediateinterior sidewall 27 that extends frombottom surface 75 for a length that is sufficient to accommodate the axial thickness ofguide ring 76. Thus, intermediateinterior sidewall 27 defines an intermediateinternal receiving compartment 100 for receivingguide ring 76, which surrounds part ofarmature 60 internally ofguide ring 76. - As shown in
Fig. 2 ,nozzle pole 70 has a thirdinterior sidewall 28 that forms a so-calleddelivery end sidewall 28, which extends from intermediateinterior sidewall 27 to the free end of the delivery end ofnozzle pole 70. Delivery endinterior sidewall 28 defines a surface shaped in a frustroconical manner and extending at an angle of about 2.5 degrees relative tocentral axis 44 so as to mirror the angle ofexterior sidewall section 73 of delivery end ofvalve seat 90. As shown inFig. 2 , the internal diameter defined bydelivery end sidewall 28 ofnozzle pole 70 in the vicinity of the delivery end ofnozzle pole 70, is slightly larger than the largest diameter ofexterior sidewall section 73 ofvalve seat 90. Moreover, the internal diameter defined bydelivery end sidewall 28 in the vicinity wheredelivery end sidewall 28 joins intermediateinterior sidewall 27 ofnozzle pole 70, is slightly larger than each of the diameter ofexterior sidewall section 72 ofvalve seat 90 and the diameter ofexterior sidewall 53 ofguide ring 76. Thus, the receivingchamber 102 defined bydelivery end sidewall 28 at the delivery end ofnozzle pole 70houses valve seat 90. In a presently preferred embodiment,delivery end sidewall 28 ofnozzle pole 70 has a maximum interior diameter of slightly more than 9.2 mm in the vicinity of the delivery end ofnozzle pole 70. The difference between the maximum diameter ofexterior sidewall section 73 ofvalve seat 90 at the delivery end ofvalve seat 90 and the maximum diameter ofdelivery end sidewall 28 ofnozzle pole 70 at the delivery end ofnozzle pole 70 is at a minimum in order to facilitate assembly and welding. - In the embodiment shown in
Fig. 2 for example, the delivery end ofnozzle pole 70 is welded to theexternal flange 86 ofvalve seat 90. Desirably, thewelds 112 are provided by a laser welder such as a neodymium-doped yttrium-aluminum-garnet (Nd:YAG) laser. This welding location onexternal flange 86 ofvalve seat 90 is sufficiently shielded fromsupport land 95 and sealingland 98 ofvalve seat 90 so as to avoid adverse effects to sealing land 98 (such as caused by excessive upward bowing oftop face 91 ofvalve seat 90, distortion oftop face 91, and all downward bowing of top face 91) of the welding's heat stress that otherwise might cause leakage. Upward bowing of sealingland 98 should be held between one and four microns for optimum sealing between sealingland 98 ofvalve seat 90 andbottom surface 62 ofarmature 60. By distortion is meant that sealingland 98 would be so contorted that no planar line of contact would exist withbottom surface 62 ofarmature 60. - As shown in
Fig. 3C for example, the exterior circumferential surface ofnozzle pole 70 is configured with acircumferential groove 111 toward the delivery end ofnozzle pole 70. As shown inFig. 2 , an external O-ring 116 can be received around thisgroove 111 ofnozzle pole 70. O-ring 116 is retained on one end by anend lip 101 ofnozzle pole 70. On the other end, O-ring 116 is retained in part by theshoulder 114 formed by the edge ofinjector body 42. In the fuel injector embodiment, an elastomeric seal such as O-ring 116 is used to sealinjector 30 in a port of the air inlet of an engine. - As known in the art, a calibration means is provided for setting the biasing means to apply a desired biasing force so as to hold the bottom surface of the armature in sealing contact with the sealing land of the valve seat. As embodied herein, a calibration slide is disposed in the
core passage 48 to provide a backstop for the biasing means such asspring 88, which applies the axial force that biases thearmature 60 against thevalve seat 90. In this way, the calibration slide provides a setting means, which is a means for setting the biasing means, such as the spring, to apply a desired biasing force so as to bias the bottom surface of the armature against the sealing land of the valve seat. Axial movement of the position of the calibration slide within the central passage of the core member adjusts the magnitude of the force applied by the spring to the armature. While a conventional calibration slide will suffice, as shown inFigs. 1 ,3A and3C , acalibration slide 125 is desirably formed from an elongated tube of spring steel. - In accordance with the present invention, the hydraulic sub-assembly of the valve includes a means for filtering fluid passing through the central fluid passage of the core member. The filtering means desirably is disposed internally of the central fluid passage of the core member. The filtering means is further desirably disposed and configured to cooperate with the biasing means so as to bias the bottom surface of the armature against the sealing land of the valve seat. The filtering means is desirably disposed between the biasing means and the setting means. In further accordance with the present invention, the filtering means is configured and disposed so that it is already assembled into the valve before the calibration slide is set and by the time the valve is flow tested during setting of the calibration slide to fix the tension applied by the spring to the armature.
- As embodied herein and shown in
Figs. 1 ,3A and3C , the filtering means includes anelongated filter 120 that is configured to fit withincentral passage 48 ofcore member 46. Rather than being positioned near thesupply end 31 of the valve as in conventional fuel injectors, the filtering means of the present invention is desirably disposed incentral passage 48 ofcore member 46 closer to thedelivery end 32 than to thesupply end 31. Moreover,filter 120 is disposed belowcalibration slide 125 in the sense thatfilter 120 is disposed closer to supplyend 32 thancalibration slide 125. Thus, during assembly ofhydraulic sub-assembly 131,filter 120 is already in place withincentral passage 48 whencalibration slide 125 is inserted to set the tension onspring 88. As shown inFig. 3A for example,filter 120 is carried by anelongated holder 118 having a cantedcompartment 119 for holdingfilter 120 at an angle with respect to the centrallongitudinal axis 44.Holder 118 also provides a centrally disposed opening (not visible in the views shown in the Figs.) through its longitudinal axis and carriesfilter 120 so as to ensure that fluid must pass throughfilter 120 before exiting the holder's conventional opening. As shown inFigs. 1 ,3A and3C for example, one end ofholder 118 is configured with a sufficient radius and gauge to butt against a rear end ofcompression spring 88. The opposite end offilter holder 118 is configured to butt against one end of acalibration slide 125. - In an alternative embodiment (not shown), the relative positions of
filter 120 andspring 88 could be reversed so thatfilter holder 118 butts againstarmature 60. However, in the preferred embodiment illustrated inFigs. 1 ,3A and3C , the moving mass is minimized by being restricted toarmature 60 andspring 88. - Desirably, each end of
calibration slide 125 is shaped identically and so that it can be inserted intopassage 48 ofcore member 46 without digging up shavings from the walls ofcentral passage 48. Otherwise, such metal shavings might clog the fluid flow passages of the valve. Moreover, becausefilter 120 is already in place withinpassage 48 whencalibration slide 125 is inserted, any such metal shavings caused by the insertion of the calibration slide would be caught byfilter 120 rather than result in either clogging or fouling either flowpassages 64 ofarmature 60 orconduits 87 ofvalve seat 90. - When the valve is flow tested during setting of the calibration slide to fix the tension applied by the spring to the armature, the filter is already installed into the valve. The presence of
filter 120 during such flow testing yields a more accurate flow test than if such testing were done without the filter present. Thus, the configuration of the present invention, permits more accurate calibration of the valve than is possible with conventional valve designs. - In accordance with the present invention, the full extent of permissible movement of the armature between its resting position when disposed against the valve seat and its actuated position when disposed against the bottom surface of the lift stop member, is known as the "lift" of the armature. In the present embodiment, the "lift" is determined by a consideration of the axial height of the armature in relation to the combined heights of the guide ring and the portion of the magnetic nozzle pole that butts against the guide ring. In the embodiment shown in
Fig. 2 , abottom surface 47 oflift stop member 80 is disposed againsttop surface 74 ofmagnetic nozzle pole 70.Bottom surface 75 ofmagnetic nozzle pole 70 is disposed to contact and rest upon atop surface 78 ofguide ring 76. Abottom surface 79 ofguide ring 76 is disposed to contact and rest uponsupport surface 97 ofvalve seat 90. As indicated inFig. 2 by the distance between opposed arrows designated by thenumber 123, the axial thickness ofarmature 60 is about 50 microns less than the sum of the axial thicknesses ofinterior wall 71 of supply end ofnozzle pole 70 andinterior wall 77 ofguide ring 76. Accordingly, the lift of the armature is about 50 microns and is schematically indicated inFig. 2 by the axial distance between the parallel straight lines disposed between the opposed arrows and labeled 123. - In further accordance with the present invention, the assembly of the valve has been greatly simplified. As shown in
Figs. 2 and6 for example, at least a first continuous weld (indicated by the row of slash lines labeled 121) is disposed to fixbottom surface 47 oflift stop member 80 totop surface 74 ofnozzle pole 70. Desirably, the welding is performed with a laser welder such as a Nd:YAG welder. As shown inFig. 2 for example, at least a second continuous weld (indicated by the row of slash lines labeled 122) (also desirably laser welds such as Nd:YAG welds) is disposed to fix a portion ofinterior sidewall surface 84 oflift stop member 80 to a portion of the exterior surface ofcore member 46. Then guidering 76 is inserted to rest againstbottom surface 75 of the supply end ofmagnetic nozzle pole 70. Thenarmature 60 is inserted to rest againstbottom surface 47 oflift stop member 80. - Next,
valve seat 90 is inserted. The stepped configuration of the circumferential exterior sidewall ofvalve seat 90 provides greater ease of assemblingvalve seat 90 into the receivingchamber 102 at the delivery end ofnozzle pole 70. Then, Nd:YAG welds 112 are used to attachvalve seat 90 to the delivery end ofnozzle pole 70 and thereby hermetically sealnozzle pole 70 tovalve seat 90. In this way,valve seat 90 forms the bottom boundary of the receiving compartment that housesarmature 60. - In accordance with the present invention, the valve is configured to enable accurate and easy setting of the valve's air gap during assembly of the valve. The desired "air gap" is the distance between the
bottom surface 56 of thecore member 46 and thetop surface 61 of thearmature 60 when thetop surface 61 of the armature rests against thebottom surface 47 of thelift stop member 80. As shown inFig. 2 , theair gap 124 is schematically indicated by the parallel straight lines disposed between the opposed arrows and labeled 124. During assembly of the hydraulic sub-assembly of the valve of the present invention, the desired air gap is set when a portion of the exterior surface of thecore member 46 is welded to theinterior sidewall surface 84 of thelift stop member 80. Thus, as shown inFig. 2 , the valve of the present invention includes a first plurality ofwelds 121 disposed to fixlift stop member 80 totop surface 74 ofnozzle pole 70, and a second plurality ofwelds 122 is disposed to fixlift stop member 80 to the exterior surface ofcore member 46. The use of the welder to weldlift stop member 80 to the exterior surface ofcore member 46 permits direct setting of theair gap 124 defined betweentop surface 61 ofarmature 60 andbottom surface 56 ofcore member 46 when upper surface ofarmature 60 is positioned againstbottom surface 87 oflift stop member 80. Moreover, thewelds - As known in the art, the size of this
air gap 124 needs to be precisely controlled, regardless of the magnitude of the gap required by the particular valve application. In a presently preferred fuel injector embodiment, thisair gap 124 is 20 microns plus or minus 6 microns. Furthermore, thesewelds lift stop member 80 prevents physical contact betweenarmature 60 andbottom surface 56 ofcore member 46 whencore member 46,armature 60, andmagnetic nozzle pole 70 are selectively actuated to form a magnetic circuit. When the welding is completed,core member 46 becomes hermetically sealed to liftstop member 80,lift stop member 80 becomes hermetically sealed tonozzle pole 70, andnozzle pole 70 becomes hermetically sealed tovalve seat 90. Thus, as shown inFig. 3C , a firsthydraulic sub-assembly 131 includes the armature 60 (not visible in this view), thecore member 46, thelift stop member 80, the guide ring 76 (not visible in this view), themagnetic nozzle pole 70, and the valve seat 90 (not visible in this view), all assembled together and hermetically sealed to one another as explained above. Thishydraulic sub-assembly 131 shown inFig. 3C can be assembled as a separate unit fromelectrical sub-assembly 132. Moreover, in accordance with the present invention, there is no need for any internally disposed O-ring for the purpose of hydraulically sealing the valve against leakage. - In a first operative condition of the valve, fluid is prevented from flowing through the valve. In a second operative condition of the valve, fluid is permitted to flow through the valve. The electrical sub-assembly includes at least one electrical component for switching the hydraulic sub-assembly from the first operative configuration to the second operative configuration. As shown in
Fig. 3B ,electrical sub-assembly 132 includesvalve body 42,body flange 49, coil assembly 50 (bobbin 52,wire 55, and terminal blades 57), andplastic jacket 34 coveringvalve body 42. Depending on whether electric current passes throughwire 55 andterminal blades 57,hydraulic sub-assembly 131 may be switched from the first operative configuration of the valve to the second operative configuration of the valve. -
Electrical sub-assembly 132 is completed whenplastic jacket 34 is molded aroundcoil assembly 50,body flange 49, andbody 42.Electrical sub-assembly 132 is configured to receive mechanical insertion ofhydraulic sub-assembly 131 intoelectrical sub-assembly 132. As shown inFig. 1 , this is accomplished by molding an axially extendingcentral channel 103 inmain branch 35 ofplastic jacket 34.Core member 46 defines an exterior surface that is configured with the same transverse cross-section aschannel 103. This complementary symmetry facilitates mechanical insertion ofhydraulic sub-assembly 131 axially intochannel 103 ofelectrical sub-assembly 132. In the embodiment shown, the exterior surface ofcore member 46 has both a constant cross-sectional shape along the length thereof and a constant diameter along the length thereof. - In the embodiments shown in
Figs. 1-6A , the components are configured with cylindrical symmetry having a circular transverse cross-section. However, cylindrical symmetry having a square or triangular or other polygonal transverse cross-section also could be employed. Moreover, the exterior and/or interior surfaces of these components can be provided with different transverse cross-sectional shapes along one or more portions of their lengths. Similarly, the shapes of the various openings and pathways through which fluid passes through the valve can be provided with different transverse cross-sectional shapes along one or more portions of their lengths, and thus need not be circular. - As shown in
Fig. 1 , whenhydraulic sub-assembly 131 is inserted intochannel 103 ofmain branch 35 ofplastic jacket 34,top bushing 40 is then inserted into receivingend 31 ofchannel 103 ofmain branch 35 ofplastic jacket 34 and welded tocore member 46 at the location generally designated 29 to securehydraulic sub-assembly 131 toelectrical sub-assembly 132. However, beforetop bushing 40 is welded tocore member 46, it becomes possible to orient one or more distinguishing features ofhydraulic sub-assembly 131 relative to one or more distinguishing features ofelectrical sub-assembly 132. For example, it becomes possible to orient theauxiliary branch 36, which containsterminal blades 57, relative to the spray pattern resulting from discharge of fluid fromoutlet conduits 87 invalve seat 90. When the desired orientation of the desired features has been set, then top bushing 40 is welded into place to fix these relative orientations of the valve's components. - Because the valve of the present invention is configured to permit
hydraulic sub-assembly 131 to be assembled separately fromelectrical sub-assembly 132, the valve of the present invention enjoys several advantages over conventional valves. For example, thehydraulic sub-assembly 131 is not subjected to the heat stresses and pressure stresses that occur whenplastic jacket 34 is molded aroundsupply end 38 of the valve'sbody 42. Moreover, the separately sealedhydraulic sub-assembly 131 can be independently checked for leakage, static flow rate, and armature lift before being combined with theelectrical sub-assembly 132. - The manufacture of a presently preferred embodiment of the valve of the present invention can be accomplished with very few machining operations. This is possible because
core member 46 andbody 42 can be cut from a piece of tubing. Moreover, bothlift stop member 80 andguide ring 76 can be formed of a fine blanked component. Furthermore, armature 60 can be molded. A small amount of secondary machining is required to finishouter surfaces armature 60.Body flange 49 can be formed of a fine blanked component or a powdered metal component. - In the closed position of the valve shown in
Fig. 2 ,bottom surface 62 ofarmature 60 rests againstupper surface 99 of sealingland 98 andsupport surface 97 ofsupport land 95. In the open position of the valve, when electric current is supplied tocoil 50,core member 46 becomes an electromagnet and forms the single working pole of a magnetic circuit in which bottom surface 56 ofcore member 46 assumes opposite magnetic polarity totop surface 61 ofarmature 60. The magnetic flux travels throughcore member 46,armature 60, andmagnetic nozzle pole 70. When this happens,armature 60 will be lifted fromsupport land 95 and sealingland 98 andarmature 60 will move vertically towardspring 88, untiltop surface 61 ofarmature 60 rests againstbottom surface 47 oflift stop member 80 to formair gap 124 therebetween. With the armature magnetically held in this position, thecentral fluid passage 48 ofcore member 46 communicates withplenum 66 andpassages 64 ofarmature 60, so that when the armature is lifted from thelands central passage 48 ofcore member 46, into theplenum 66 of thearmature 60 and through thepassages 64 of the armature and tointerior surface 94 oftop face 91 ofvalve seat 90. From there the fluid passes throughentrance openings 85 andoutlet conduits 87 of thevalve seat 90. In the injector embodiment, the fuel issuing from theconduits 87 throughexit openings 89 is atomized and flows through thevalve seat 90 into an air inlet duct of the associated engine.
Claims (10)
- An electromagnetically actuatable disc-type valve for metering the supply of fluid, the valve comprising:an elongated cylindrical core member (46) having an exterior surface including a bottom surface (56), said core member (46) defining a hollow passage (48) internally thereof;an armature (60) having a top surface (61) disposed toward said bottom surface (56) of said core member (46), said armature (60) having a bottom surface (62) disposed to face opposite said top surface (61) of said armature (60);a lift stop member (80) formed of non-magnetic material, said lift stop member (80) being configured in the form of a first annular sleeve with an axial opening configured to receive a portion of said core member (46) therein;a valve seat (90) configured in the form of a first disc having a top face (91) disposed toward said bottom surface (62) of said armature (60), said top face (91) including a top surface (94), said valve seat (90) defining at least one entrance opening (85) through said top surface (94), said valve seat (90) defining at least one sealing land (98) surrounding all said entrance openings (85) and having an upper surface (99) raised above said top surface (94) of said valve seat (90);a nozzle pole (70) configured in the form of a second annular sleeve, said nozzle pole (70) defining a supply end and a delivery end disposed axially opposite said supply end, said nozzle pole (70) defining an interior wall (71) at said supply end, at least part of said interior wall (71) defining at least part of a first receiving compartment, said armature (60) being at least partially received within said first receiving compartment;each of said core member (46), armature (60) and nozzle pole (70) being formed of magnetic material and configured and disposed together to be selectively actuated to form part of a magnetic circuit with a single working pole at said bottom surface (56) of said core member (46);a guide ring (76) formed of non-magnetic material and configured in the form of a third annular sleeve, said guide ring (76) being disposed to prevent physical contact between said armature (60) and said nozzle pole (70) when said core member (46), said armature (60) and said nozzle pole (70) are selectively actuated to form part of said magnetic circuit;a first weld (121) for welding said nozzle pole (70) to said lift stop member (80); anda second weld (122) for welding said lift stop member (80) to a portion of said exterior surface of said core member (46) in a manner defining an air gap (124) of a predetermined magnitude between said top surface (61) of said armature (60) and said bottom surface (56) of said core member (46) when said core member (46), said armature (60), and said nozzle pole (70) are selectively actuated to form part of said magnetic circuit.
- A valve as in claim 1, further comprising a third weld (112) for welding said nozzle pole (70) to said valve seat (90) at a location of said valve seat (90) sufficiently shielded from said sealing land (98) of said valve seat (90) so as to prevent downward bowing of said sealing land (98) of said valve seat (90).
- A valve as in claim 1, further comprising a third weld (112) for welding said nozzle pole (70) to said valve seat (90) at a location of said valve seat (90) sufficiently shielded from said sealing land (98) of said valve seat (90) so as to prevent excessive upward bowing of said sealing land (98) of said valve seat (90).
- A valve as in claim 1, further comprising a third weld (112) for welding said nozzle pole (70) to said valve seat (90) at a location of said valve seat (90) sufficiently shielded from said sealing land (98) of said valve seat (90) so as to prevent excessive distortion of said sealing land (98) of said valve seat (90).
- A valve as in claim 1, further comprising a third weld (112) for welding said nozzle pole (70) to said valve seat (90), and wherein said first, second, and third welds (121, 122, 112) being configured and disposed to hermetically seal the valve and prevent leakage of fluid during operation of the valve, and wherein:said nozzle pole (70) defining a delivery end interior sidewall (28) at said delivery end of said nozzle pole (70), at least part of said delivery end interior sidewall (28) defining a receiving chamber (102), said valve seat (90) being received within said receiving chamber (102), said nozzle pole (70) defining an intermediate interior sidewall (27) between said supply end and said delivery end of said nozzle pole (70), said intermediate interior sidewall (27) defining an intermediate internal compartment (100), said guide ring (76) being received within said intermediate internal compartment (100).
- A valve as in claim 1, wherein:said exterior surface of said core member (46) is configured as a right cylinder with a circular transverse cross-section, and said hollow passage of said core member (46) is configured as a right cylinder with a circular transverse cross-section.
- A valve as in claim 1, further comprising:a means (88) for biasing said bottom surface (62) of said armature (60) against said sealing land (98) of said valve seat (90), said biasing means (88) being at least partly disposed internally of said passage (48) of said core member(46) ; anda means (120) for filtering fluid passing through said passage of said core member (46), said filtering means (120) being disposed internally of said passage (48) of said core member (46) and further disposed and configured to cooperate with said biasing means (88) to bias said bottom surface (62) of said armature (60) against said sealing land (98) of said valve seat (90).
- A valve as in claim 7, further comprising a means (125) for setting said biasing means (88) to apply a desired biasing force to bias said bottom surface (62) of said armature (60) against said sealing land (98) of said valve seat (90), said filtering means (120) bering disposed between said biasing means (88) and said setting means (125).
- A valve as in claim 1, wherein said valve seat (90) defines a supply end and a delivery end disposed axially opposite said supply end, said supply end of said valve seat (90) further defining an axially extending exterior surface (72) defined by a first diameter, said delivery end of said valve seat (90) further defining a generally axially extending exterior surface (73) that is diverging to a second diameter larger than said first diameter of said supply end, said nozzle pole (70) being welded to a portion of said diverging exterior surface (73) of said delivery end of said valve seat (90).
- A valve as in claim 1, wherein said armature (60) is configured in the form of a disc having a cylindrically-shaped outer side surface (63) defined by an exterior diameter;said guide ring (76) having a top surface (78) and a bottom surface (79) opposed to said top surface (78) of said guide ring (76), said guide ring (76) having a cylindrically-shaped interior side surface forming a central opening defined by an interior wall (77) having an axial length extending from said top surface (78) to said bottom surface (79) of said guide ring (76); andsaid axial length of said guide ring (76) being configured in relation to said exterior diameter of said armature (60), the amount of lift permitted said armature (60) between said lift stop member (80) and said top surface (61) of said armature (60), and the diametrical clearance between the central opening of said guide ring (76) and said cylindrically-shaped outer side surface (63) of said armature (60), so as to preclude jamming of said armature (60).
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
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US08/916,963 US5979866A (en) | 1995-06-06 | 1997-08-19 | Electromagnetically actuated disc-type valve |
US916963 | 1997-08-19 | ||
PCT/US1998/012301 WO1999009342A1 (en) | 1997-08-19 | 1998-06-12 | Electromagnetically actuated disc-type valve |
Publications (3)
Publication Number | Publication Date |
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EP1003990A1 EP1003990A1 (en) | 2000-05-31 |
EP1003990A4 EP1003990A4 (en) | 2005-01-19 |
EP1003990B1 true EP1003990B1 (en) | 2009-04-08 |
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Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP98931257A Expired - Lifetime EP1003990B1 (en) | 1997-08-19 | 1998-06-12 | Electromagnetically actuated disc-type valve |
Country Status (8)
Country | Link |
---|---|
US (1) | US5979866A (en) |
EP (1) | EP1003990B1 (en) |
AT (1) | ATE428077T1 (en) |
AU (1) | AU8142398A (en) |
BR (1) | BR9811202A (en) |
CA (1) | CA2300258A1 (en) |
DE (1) | DE69840722D1 (en) |
WO (1) | WO1999009342A1 (en) |
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GB2124554B (en) * | 1982-07-29 | 1985-12-24 | Lucas Ind Plc | Manufacture of valve seats |
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GB2144177B (en) * | 1983-07-28 | 1987-01-07 | Lucas Ind Plc | Fuel injector |
GB2144201B (en) * | 1983-07-28 | 1986-10-22 | Lucas Ind Plc | Fuel injector valve seat |
GB8327527D0 (en) * | 1983-10-14 | 1983-11-16 | Lucas Ind Plc | Fuel injector |
US4572436A (en) * | 1984-12-24 | 1986-02-25 | General Motors Corporation | Electromagnetic fuel injector with tapered armature/valve |
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GB2190426B (en) * | 1986-05-16 | 1989-12-06 | Lucas Ind Plc | Fuel injectors |
GB8611949D0 (en) * | 1986-05-16 | 1986-06-25 | Lucas Ind Plc | Fuel injectors |
GB8611950D0 (en) * | 1986-05-16 | 1986-06-25 | Lucas Ind Plc | Gasoline injector |
GB8718732D0 (en) * | 1987-08-07 | 1987-09-16 | Lucas Ind Plc | Fuel injector |
US4787418A (en) * | 1987-09-15 | 1988-11-29 | Colt Industries Inc. | Valve assembly and fuel metering apparatus |
GB8725176D0 (en) * | 1987-10-27 | 1987-12-02 | Lucas Ind Plc | Gasolene injector |
EP0328277B1 (en) * | 1988-02-05 | 1993-03-24 | Lucas Industries Public Limited Company | Fuel injector |
DE3825134A1 (en) * | 1988-07-23 | 1990-01-25 | Bosch Gmbh Robert | ELECTROMAGNETICALLY ACTUABLE VALVE AND METHOD FOR THE PRODUCTION THEREOF |
US4941447A (en) * | 1989-02-21 | 1990-07-17 | Colt Industries Inc. | Metering valve |
US5070845A (en) * | 1989-05-22 | 1991-12-10 | General Motors Corporation | Fuel injection nozzle |
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US5054691A (en) * | 1989-11-03 | 1991-10-08 | Industrial Technology Research Institute | Fuel oil injector with a floating ball as its valve unit |
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IT1240173B (en) * | 1990-04-06 | 1993-11-27 | Weber Srl | ELECTROMAGNETICALLY OPERATED FUEL INJECTION DEVICE FOR AN INTERNAL COMBUSTION ENGINE |
US5086980A (en) * | 1990-10-09 | 1992-02-11 | Ford Motor Company | Fuel injector for an internal combustion engine |
DE4131535A1 (en) * | 1991-09-21 | 1993-03-25 | Bosch Gmbh Robert | ELECTROMAGNETICALLY OPERATED INJECTION VALVE |
IT1250846B (en) * | 1991-10-11 | 1995-04-21 | Weber Srl | ELECTROMAGNETIC-OPERATED FUEL DOSING AND PULVERIZING VALVE WITH VERY LOW DIMENSIONS |
IT1250845B (en) * | 1991-10-11 | 1995-04-21 | Weber Srl | ELECTROMAGNETICALLY OPERATED FUEL DOSING AND PULVERIZING VALVE FOR AN ENDOTHERMAL MOTOR FEEDING DEVICE |
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US5381965A (en) * | 1993-02-16 | 1995-01-17 | Siemens Automotive L.P. | Fuel injector |
DE4325842A1 (en) * | 1993-07-31 | 1995-02-02 | Bosch Gmbh Robert | Fuel injection valve |
US5417373A (en) * | 1994-02-10 | 1995-05-23 | Siemens Automotive L.P. | Electromagnet for valves |
US5544816A (en) * | 1994-08-18 | 1996-08-13 | Siemens Automotive L.P. | Housing for coil of solenoid-operated fuel injector |
US5722367A (en) * | 1995-10-10 | 1998-03-03 | Walbro Corporation | Engine idle speed air control |
US5769328A (en) * | 1995-12-26 | 1998-06-23 | General Motors Corporation | Fuel interconnect for fuel injector |
-
1997
- 1997-08-19 US US08/916,963 patent/US5979866A/en not_active Expired - Lifetime
-
1998
- 1998-06-12 DE DE69840722T patent/DE69840722D1/en not_active Expired - Lifetime
- 1998-06-12 BR BR9811202A patent/BR9811202A/en active Search and Examination
- 1998-06-12 AU AU81423/98A patent/AU8142398A/en not_active Abandoned
- 1998-06-12 WO PCT/US1998/012301 patent/WO1999009342A1/en active Application Filing
- 1998-06-12 AT AT98931257T patent/ATE428077T1/en not_active IP Right Cessation
- 1998-06-12 EP EP98931257A patent/EP1003990B1/en not_active Expired - Lifetime
- 1998-06-12 CA CA 2300258 patent/CA2300258A1/en not_active Abandoned
Also Published As
Publication number | Publication date |
---|---|
BR9811202A (en) | 2000-07-18 |
WO1999009342A1 (en) | 1999-02-25 |
AU8142398A (en) | 1999-03-08 |
ATE428077T1 (en) | 2009-04-15 |
EP1003990A4 (en) | 2005-01-19 |
EP1003990A1 (en) | 2000-05-31 |
CA2300258A1 (en) | 1999-02-25 |
US5979866A (en) | 1999-11-09 |
DE69840722D1 (en) | 2009-05-20 |
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